Tote bags of powder ingredients are hoisted into the bulk bag discharger stations. “It was necessary to plan with the subcontractors daily to execute the project in a timely fashion.” “We had to work through it by planning ahead and working inside out,” he says. The site constraints only allowed for one 12-ft-wide access point for a majority of the work until DSC was tied into the existing structures within the processing area addition, according to Thomas Patterson, DSC field engineer. “A new 4,240-sq-ft process addition with a 1,500-sq-ft mezzanine was built for the installation of new batch cooking process and powders handling, as well as a 450-sq-ft addition for project utilities.” “DSC utilized 3D scanning technology and drones in the design process due to existing site constraints,” Snyder explains. “Overcoming this challenge required clear communication between the project team, from contractors to engineers and plant leaders, to ensure everyone was clear on the process,” adds Phil Tuttle, Wausau facility sanitation manager.ī&G Foods, Liffey Meats, Graphic Packaging, and More Protect the PlanetĬonstruction technologies include 3D scanning and dronesĭean Snyder Construction (DSC) provided preliminary design, cost-estimating, engineering, general construction, and commissioning services for the Wausau facility to meet the new processing requirements, according to Dale Snyder, DSC owner, CEO, and project manager. “The biggest challenge we had in running the old and new lines simultaneously was ensuring we maintained our unwavering commitment to product and personnel safety during the transition of the CIP systems,” says John Schmelzer, production supervisor for Kraft Heinz. “Our facility team on the ground was excellent in communicating with project partners to help drive clarity.”ĭespite pandemic and supply chain obstacles, the Wausau project was delivered on time. “Due to our health and safety protocols, we were required to handle aspects of the project remotely, rather than our normal hands-on approach,” she says. Photo courtesy of Kraft HeinzThe pandemic definitely was a factor throughout the project, says Amanda Mandefro, Wausau plant manager. The cook room features specially sized tanks, actuated valves, and transfer pumps that select precise batches and transfer six different liquids to the respective cookers. entered 2020 and project work began, no one knew how disruptive the emerging coronavirus would be to food processors, their customers, and consumers, as well as food industry equipment providers. “New equipment was designed to be safe and ergonomic for plant operators,” says Brian Bernard, president of Spec Engineering, a Gray company, “increasing production rates from 7,000 lb/hr to 10,500 lb/hr.”īut as the U.S.
The new production system also required building upgrades and expansions with changes to the previous process, including all new powder and liquid handling equipment and a complex clean-in-place (CIP) system. This project received a 2021 Manufacturing Innovation Award from ProFood World. Kraft Heinz’s facility in Wausau, Wis., implemented a recent 20,000-sq-ft building expansion and plant modernization project for the Kraft Macaroni & Cheese blue box product during the pandemic without affecting product quality or taste.
But as we hopefully enter a less restricted and less virus-ridden era, Kraft Heinz is betting that its mac and cheese product will continue to deliver the food consumers love.
Everything and anything in moderation sounds much more like a reality-based eating trend. So much for consumers saying they want to cut back on fatty foods. In fact, the much-loved product even comes in an ice cream flavor made by Van Leeuwen Ice Cream, produced in limited editions. Even in today’s era of consumers searching for fresh food choices, the iconic, shelf-stable comfort food still packs a punch. Kraft's macaroni & cheese has been on the market for more than 80 years.