Manufacturing modernization

"creating new value from existing facilities" These Owners Have Used Bogner to upgrade their manufacturing facilities and/or processes to maximize their competitiveness:

The firms listed here have used Bogner Construction Company to evaluate facilities expansion possibilities, rehabilitate manufacturing facilities, rebuild/replace processing equipment, and provide a variety of related value management services. We encourage you to contact them regarding our level of service.

Frito-Lay, Inc., Wooster, Ohio

The J.M. Smucker Company, Orrville, Ohio

The Will-Burt Company, Orrville, Ohio

Wayne-Dalton Corporation, Mt. Hope, Ohio

The Wooster Brush Company, Wooster, Ohio

Rubbermaid, Inc., Wooster, Ohio

United Titanium, Wooster, Ohio

Holmes Cheese Company, Millersburg, Ohio

Alpine Cheese Company, Wilmot, Ohio

Plymouth Foam, Inc., Plymouth, Wisconsin

The Challenge:

There is no doubt about it; upgrading manufacturing facilities can be a challenge. The necessity for the owner to maintain high levels of production while changes are being made to a facility can create unusual problems. Bogner Construction Company has the experience, manpower, and equipment necessary to minimize the impact of upgrading your facility or manufacturing process.

The Planning:

"Planning is critical," says Bob Bogner. "The key to maximizing your production while we are making changes, is to involve your people and ours very early in the process with a totally team oriented project planning approach."

During the planning process, the team decides how the project can best be broken down into manageable phases with each job being carefully scheduled to minimize potential down time. Materials must be ordered and on hand; equipment and manpower must be effectively teamed to get the greatest amount of work done in the shortest amount of time.

Special Attention Must Be Given To:

Safety of all personnel

Unloading and material staging area(s)

Maintaining good communications among all those involved in the project

Safe and efficient routing through production area(s)

Containment of dust and debris to the project area

The possible need to relocate and/or install temporary process piping and/or electrical connections

Evaluation of alternate work plans in case of changes in the owner's production schedule

"Considering all of the above, it increases our efficiency and minimizes your frustration. We know how to give you what you need and, no matter how demanding your production schedule, we will be ready to do our part when you are ready for us." -Bob Bogner

Frito-Lay Inc., Wooster, Ohio

Frito-Lay, Inc., a nationwide manufacturer of potato chips and snack foods, decided to renovate its existing 95,000 square-foot plant, which was originally constructed by Bogner in 1948. Bogner Construction Company negotiated the contract to upgrade and expand this plant into a modern upscale 151,000 square-foot facility which would include new plant offices and be over two hundred percent more productive. Frito Lay Rehabilitation

The job entailed upgrading of the building and the replacement of all production equipment while remaining under USDA inspection. The owner also retained the services of a private food plant inspection firm, which had total project control. I.E. They could demand immediate compliance. Frito-Lay allotted 157 days for the total project, with only 20 days of that time set aside for a total plant shut down.

200 Workers … 24/7:
- In order to meet the latter deadline, some operations were carried on around the clock, seven days a week. At times, over two hundred workers were employed on the project. Bogner Construction Company needed only twenty-three of its alloted thirty days to complete all shutdown related operations.
16,000 Sq. Ft. Above Existing:
- In order to install computerized packaging equipment, part of this work entailed installing a 16,000 square-foot addition over the existing plant. Steel erection and foundation installations were coordinated with the owner's production schedule. The existing roof was used as a working surface to install structural steel, exterior insulated metal siding, roofing, all mechanical ductwork, and a new ceiling including lights, fire sprinklers and HVAC diffusers.
Total Project Control:
- Bogner Construction Company managed the project, serving as general contractor with total project control. The entire project was completed and turned over to the owner in 143 days, 14 days ahead of schedule.

Three Projects … One Location

Bogner built and later expanded what was originally the Rexroth, Inc. facility shown at the top of this photo. It is currently owned and managed by D&S Transportation. Bogner constructed the original facility at the bottom of this photo for Diebold, Inc. We then completed a major upgrade for Crown Divisions of the Allen Group. After Crown Divisions sold it to The Wooster Brush Company, Bogner was once again called on to renovate and upgrade the facility.

BOGNER CONSTRUCTION COMPANY ... SINCE 1897

Experienced in servicing a broad spectrum of clients:

The J. M. Smucker Company, Orrville, Ohio

5 plant expansions, 3 warehouse facilities, 6 corporate office buildings, a 500,000 GPD Phase I anaerobic wastewater treatment plant and a 200,000 GPD Phase II expansion
Total relocation of every piece of bottling and packaging equipment on two separate occasions, while the owner maintained full operations

The Will-Burt Company, Orrville, Ohio

New manufacturing facility and total relocation of all manufacturing equipment including the paint line which required EPA approval

Wayne-Dalton Corporation, Mt. Hope, Ohio

2 new manufacturing facilities, 60,000 sq. ft. each
Rehabilitation of 180,000 square feet

Frito-Lay, Inc., Wooster, Ohio

4 plant expansion projects
2 major rehabilitations

Volvo GM Heavy Truck Plant, Orrville, Ohio

Total plant renovation, including a new paint line

(Please call us for additional information regarding any of the above mentioned projects.)

Is Rehabilitation For You?

Let Bogner Construction Company help you decide whether rehabilitation or new construction best suits your needs.

STRUCTURAL AND SPACE ANALYSIS

These two procedures are the first steps toward determining the feasibility of any manufacturing upgrade project. An overall project analysis determines whether the square footage that results from renovation rehabilitation is worth the expenditure involved. A structural analysis determines the potential for possible rearrangement or expansion of inner space.

MECHANICAL/ELECTRICAL/PROCESS PIPING ANALYSIS

Recommendations are given to bring the structure up to current building standards in the areas of plumbing, electrical, heating, ventilating, fire protection and air-conditioning.
A process Piping/Electric Analysis will determine if current in-plant utilities are capable of supporting the new requirements.

EXTERIOR RESTORATION ANALYSIS

A careful study of the existing building exterior to determine the potential for and estimate the economics of both aesthetic requirements and such facilities as truck docks, tanks farms, etc.