Case Study • Meat Processing
Confidential Client Ground Beef Line Execution
350,000 lbs/week line in just 6 months
Rapidly engineered, permitted, and installed to minimize downtime. Strategic development allowed lower rate production to proceed key weeks before full commissioning, creating early client return.
Fast-Track Turnkey Execution Timeline
Complex Facility Setup
Live operational retrofits based in LA
12 Trade Contractors
Simultaneously synchronized by DPS
Minimized Interuption
Only 4 weeks cumulative downtime
Revenue Extraction
Activated key production early
Key Performance Successes
Critical Timelines • High Performance Results
350K lbs
Beef Volume Weekly
Substantial volume increase with clean room slicing, loading and sealing integration.
6 Mos
Turnkey Execution
All permitting, structural updates, mechanical placement, and utility alignment.
4 Wks
Downtime Contained
Ongoing commercial deliveries remained prioritized with minimal offline impact.
Wk 11 Go
Early Production
Lower-rate operations deployed weeks ahead of full validation checklist completion.
Case Context
The Challenge: Installing High-Volume Capacity in Concurrently Running Facility
The client required a major capacity expansion inside an existing, highly active Los Angeles manufacturing plant with a target of installing a massive 350,000 lbs/week high-capacity ground beef processing line.
With peak sales season looming, shutting down operational segments was out of the question; cumulative production timeline disruptions could not exceed four weeks. Fire protection codes, local permits, and physical mechanical moves had to occur concurrently while other lines maintained volume.
DPS METHODOLOGY
Design • Build • Manage – Dynamic Alignment
Stage One
DESIGN
All disciplines engineered within 4 weeks. Key process assets ordered first to eliminate logistics delivery lag. Fully reconciled fire suppression system within existing layout parameters.
Stage Two
BUILD
Turnkey field representation managing 12 specialty contractors. Handled processing room relocations, slab adjustments, utility piping hooks, and sanitation boundary walls cleanly.
Stage Three
MANAGE
Focused project management with weekly dashboarding logic. Designed and activated phased production by Week 11, giving the client early market capitalization months before baseline closeout.
EXECUTION TIMELINE
Phased Relocation & Capacity Delivery Timeline
Turnkey Delivery Completion
Weeks 1–4
Engineering & Permits
Structural, MEP designs calculated. Immediate equipment acquisitions placed. Approvals fully released in Los Angeles county.
Weeks 5–10
Installation & Retrofit
Under-floor utility trenches cut, process pipes distributed. Line assets positioned and existing processing room relocated elegantly.
Week 11 🎉
Early Production
Relocated slicing room delivered. Early lower-rate operations initialized to protect active product supply goals.
Weeks 12–20
Full Integration
Fire prevention safety nets run, complex control calibrations finished and SCADA systems certified with only 4 weeks operational gap.
Month 6
Full Scale Achieved
Ground beef line running at maximum 350,000 lbs/week layout with zero delay or supply defaults reporting.
PROJECT GALLERY
Installation & Validation Phase Images
Equipment Placement Grid
Packaging & Sealing Assembly
Rigging & Transport SetupClean Slicing Conveyor Section
Conveyor Line Level Validation
Material Loading Systems Setup
Meat Slicing Module Section
Product Press Form Systems
Pneumatics & Controls Setup
Primary Framing Setup
Piping Lines Structural Checks
Overhead Fluid Utilities Distribution
Sanitary floor trench drainage cutting
Overhead Water Header Assembly
Hygienic Valves Setup Phase
Process Steam Distribution Network
Conductor termination sets in primary panel
PLC panel alignment and control wires mapping
Fire prevention flow manifold loop
Safety System Alarm Integration
Validation & CIP System CalibrationsCLIENT VOICE
“DPS delivered our ground beef line faster than any partner we’ve ever worked with. The early production at week 11 allowed us to capture peak season sales we would have otherwise missed.”
Operations Director
Confidential Client — Leading Meat Processor
Performance Highlights
- Total physical downtime
- Only 4 weeks
- Early revenue generated
- Week 11
- Coordinated subcontractors
- 12 Trades
Senior Lead Design Team Review
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Let’s map out how DPS can deliver your next processing installation, equipment retrofit, or complex meat facility expansion with matching timeline security and minimized downtime.
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