CASE STUDY
New Ready Meals Factory – Design and Equipment
Project management of a multi-million-pound scheme to deliver manufacturing excellence for a new Ready Meals Factory in Texas, USA.
The Challenge
With the development of a new factory in Texas, our client required a comprehensive production review to ensure capacity planning, process flows, and equipment procurement were able to meet the specific requirement of their customers.Delivering Success
Protolan applied a four-stage process including feasibility, design and procurement, implementation, and commissioning. Our project engineers worked alongside our client to co-ordinate front-end capacity work which enabled a process flow model to be interactive and specifically identify bottlenecks. Equipment specification comprised of the selection, coordination, delivery and installation and commissioning of all preparation, cooking, cooling, packaging and ancillary equipment to ensure the customer had all elements necessary to launch a high volume, multi-component ready meals process. Protolan delivered a multifaceted approach utilising 3D modelling to ensure that specialist process equipment procured from United States, Canada, Germany, Italy and UK were all coordinated, delivered, installed and commissioned within the facility. Protolan advised on building and infrastructure to ensure best practice hygienic design across the factory. This successful project is now operational and delivering products for our client’s customers.Services Employed
Project Engineering
Project Management
Capacity Planning
Process Flow Analysis
Equipment Specification
Commissioning
“Having worked alongside Protolan previously installing a liquids bottling line, we chose James and his team to assist because we knew we could rely on their knowledge and expertise to deliver the right result. The hygiene and changeover process improvement project was delivered professionally and on time. I would not hesitate to recommend Protolan and will definitely use them again in the future should the need occur.”
- Richard Greathead, Chief Executive
Nutrition Group PLC
“The Protolan team have been an important part in the success of our recent, complex projects. They are a dedicated partner who are responsive, client-conscious and own a wealth of food manufacturing knowledge. Protolan’s project team worked closely with our internal team to deliver a multifaceted project, providing innovative solutions to ensure best practice across the factory. They show great diligence and flexibility when faced with project challenges. I look forward to a continued relationship with Richard and his team and would not hesitate to recommend them.”
- Gary McEvoy (General Manager)
Bakkavor Texas
“I have worked with Protolan over numerous years and am more than happy to recommend them to deliver our projects. They understand our business and are skilled in utilising their extensive food manufacturing expertise to support our complex needs. They have the foresight to identify possible issues and give solutions that are effective, offering genuine insight for our business. The Protolan team provide an experienced, knowledgeable and straight-talking resource. It is a pleasure to work with them.”
- Simon Wood (Chief Engineer)
Hotel Chocolat
“Protolan show great understanding of the food industry. They have the leadership, food expertise and project management skills to understand our challenges and familiarise themselves with our business objectives. Their concise communication provided us with a clear view of the issues and challenges of the project, providing us with a tangible project plan and a successful scheme.”
- Sally Mitchell
Saladworks
“Having worked with Protolan on several major projects, I am always impressed by their expertise within the food industry and positive attitude. They fully integrated into our team and that of the wider business, understood our challenges and delivered a tangible plan guided by solid project management and engineering practices. They have been a pleasure to work with and we will continue to work with them on future projects.”
- Jason Kelly (Head of Operations - Core Produce)
Morrisons
"Having worked with Protolan on previous projects, Revolution Foods had no hesitation to engage them to collaborate with us on a new project in challenging times.
Protolan work with us in complete partnership, ensuring they understand the scope of our requirements and the challenges involved. Thorough, responsive, and professional, Protolan ultimately brought our project to a successful conclusion.
I would have no reservation in recommending Protolan."
- Jose Morales Senior
Director of Operations Revolution Foods