Midwest Natural Cheese Greenfield
A regional dairy cooperative needed a new natural and process cheese facility — designed, permitted, and commissioned as a single fixed-price engagement. PES delivered all seven disciplines under one contract, with utility systems pre-matched to process loads from day one.
- Vat room, aging cave, and packaging hall — single integrated layout
- Ammonia refrigeration and glycol distribution, pre-sized to process load
- CIP system fully integrated with PLC/SCADA controls architecture
- USDA HACCP zone layout, air classification, and floor drainage design
- Completed 3 weeks ahead of milestone — no change orders issued
"Having one contract for all seven disciplines eliminated the finger-pointing we'd seen on every project before this. When a utility didn't match a process load, there was one team responsible for fixing it — and they did."
Craft Beverage Line Addition — Hot-Fill PET
A growing craft tea and juice producer needed a hot-fill PET line added to an existing facility — with minimal production disruption. The PES package covered every element from filler specification through palletizer integration, electrical tie-in, CIP, and controls update — all scoped and priced before the contractor was engaged.
- Line balance model developed prior to OEM engagement — equipment selected to hit target OEE
- Hot-fill filler, tunnel cooler, labeler, case packer, and palletizer integration
- Electrical tie-in to existing MCC with load validation and arc flash study update
- CIP loop redesign to serve both existing and new line from shared CIP skid
- Line commissioned over a single 10-day planned shutdown — on schedule
"We'd been quoted 6 weeks just to get a proposal from a traditional firm. PES came back in 72 hours with a fixed price and a scope we could hand directly to our CFO."
Pickle & Relish Line — Brownfield Integration
A mid-size pickle and relish producer needed a new glass jar line integrated into an aging facility with constrained utilities and limited floor space. The PES package was scoped to work within existing electrical capacity, optimize the floor layout for throughput, and include brine batching, CIP, USDA zoning, and pasteurization as a single fixed-price scope.
- Brine/vinegar batching, blending tank, and in-line pH monitoring
- Glass jar filler, lidder, vacuum sealer, and tunnel pasteurizer specification
- USDA zone layout, floor drain redesign, and waste stream (brine) management
- Electrical load analysis confirmed existing MCC capacity — avoided $280K substation upgrade
- PLC/HMI tied into existing SCADA without platform migration
"The electrical load analysis alone saved us more than $280K on a substation we didn't need. That's the difference between an integrated scope and a discipline-by-discipline approach."
Corrugated Converting Facility — Greenfield
A regional packaging company expanding into corrugated needed a complete new facility — corrugator hall, converting floor, starch system, warehouse, dock, and all utilities — designed for 24/7 operation and commissioned as a single fixed-price contract. The PES package integrated all seven disciplines from site through production startup.
- Corrugator hall layout, single-facer line, and converting floor with multi-line flexibility
- Starch preparation system, ink mixing room, and roll storage design
- Facility-wide dust collection — corrugator, converting, and trim systems
- Full MES and plant controls architecture — single-pane visibility across all lines
- Warehouse dock design with AGV pathway integration pre-conditioned in floor slab
"We'd never built a corrugated facility before. A single contract covering everything — from site prep to the first board out the door — let our team stay focused on operations, not managing 12 different contractors."