Client: ONCE AGAIN NUT BUTTER
I recognized that Re:Build Optimation had a lot of expertise there and a lot of transplanted ex-Kodak people that really knew a lot about all sorts of manufacturing, manufacturing processes and could do equipment installs and refurbishing. They fill a void because it’s as close to having that expertise under your roof as it can be without actually hiring people full time.
– ROBERT GELSER, PRESIDENT AND GENERAL MANAGER OF ONCE AGAIN NUT BUTTER
A U.S.-based food manufacturer needed to expand its nut butter production capabilities to meet increasing demand, reduce production costs, and comply with evolving food safety requirements. The company planned to build a new 40,000-square-foot facility dedicated to peanut butter production, with a critical requirement to isolate peanut processing from other allergen-sensitive operations.
The manufacturer had historically managed equipment installation in-house but found it increasingly difficult to coordinate across vendors and trades during a multi-phase expansion. They sought a local partner that could deliver engineering, fabrication, construction, and automation services under one roof, with the experience to handle the entire project lifecycle and provide ongoing support.
Re:Build Optimation was selected to serve as the turnkey project partner and began by developing preliminary process layouts and flow diagrams. Working alongside a third-party peanut butter process consultant, Re:Build Optimation refined system requirements, sized equipment, and developed utility specifications for systems such as compressed air and hot water.
Following preliminary engineering, Re:Build Optimation completed detailed engineering, integrated the process design with the building architecture, and led collaborative design reviews with production operators. The team produced a full specification package, bills of materials for roughly 400 fabricated and purchased components, and a fully coordinated process and facility layout.
Skilled trades fabricated and installed custom process equipment, including ducts, chutes, hoppers, platforms, shelving, and mezzanines. Millwrights and electricians handled the installation of all fabricated and purchased equipment, along with electrical and mechanical utilities. Re:Build Optimation also provided construction management to coordinate the installation schedule and minimize delays.
Automation engineers delivered PLCs and HMIs to control and monitor each stage of the production process. The team also supported system startup, debug, and ongoing maintenance to ensure long-term reliability and adaptability.
The turnkey solution included:
Despite equipment arriving without detailed drawings or controls, Re:Build Optimation’s in-house controls engineering team adapted quickly, adding custom control panels and electrical disconnects to fit the facility’s needs.
The upgraded facility allowed the client to scale peanut butter production significantly while reducing operational risk, labor content, and cost. Designed with growth in mind, the plant can accommodate new equipment to double output again in the future. By partnering with Re:Build Optimation, the client gained a trusted long-term partner capable of supporting both immediate needs and future expansion.
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