CASE STUDY
Revolution Foods New SCA Facility
Revolution Foods are a school and community meal provider manufacturing healthy meals across the US -delivering around 2 million meals a week to 2,500 schools and community sites.
The Challenge
Protolan worked with Revolution Foods on two projects to deliver a new facility fit for purpose and in-line with future ambitions. The initial project looked to manage a facility move within Southern California to a new facility in La Mirada. Once the initial transition was complete, Protolan were asked to work with Revolution Foods on an expansion of the La Mirada site to increase capacity. Having worked with Revolution Foods on previous projects, Protolan were able to manage workstreams effectively across the business.Project One – Facility Relocation
Protolan implemented a $1M factory transition from the existing Southern California facility to a new c.80ksqft building in La Mirada.Protolan were responsible for:
- Budget and schedule management of all workstreams
- Management of general contractor and design house to develop cost effective layout that meets all agency and department requirements
- Scope of works management and quality control to ensure build and making good of existing facility up to code specification
- Managed equipment and production transfer from site-to-site utilizing capacity drops and down days
- Ensuring efficient workstream management ranging from HR to QC to Operations to deliver a successful project for all departments
- Coordination of agency inspections and final sign offs alongside site team
Project Two – New Facility Expansion
Protolan managed a required expansion at the new La Mirada site during the Covid-19 Pandemic to provide additional capacity. An investment of $1.2M then allowed Revolution Foods to provide meals to the homeless population. Protolan were responsible for:- Managing the internal remodelling to expand useable ancillary areas of the facility to ensure increased capacity from the current production room.
- Feasibility assessment on final layout of the site to ensure all investment was in line with future expansion plan for the facility.
- Managing the tender process for contractors and ensuring best practice.
- Managing scope and change management across all areas
- Added c.6ksqft chilled finished goods storage
- Added c.6ksqft dispatch and washing room
- Reworked production areas and facility flows to best utilise new and existing remodelled areas
- Remote permit submission and plancheck management
Delivering Success
This project was implemented during the Covid-19 Pandemic, which came with its own challenges. Protolan worked remotely with Revolution Foods, working closely with site teams to ensure the project was delivered successfully. It was important that we remained adaptable and reactive, due to changes in funding and rescoping of brief for a cost-effective build. This included direct discussion and management with City Officials to fast-track plans through Covid-19 to ensure Revolution Foods would meet project timelines.Services Employed
Project Management
Project Engineering
Factory Design
Capacity Planning
“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