Case Study • Food Manufacturing

Golden West Food Group
Co-Packing Plant Relocation

18M facility delivered in just 10 weeks

From groundbreaking to Temporary Certificate of Occupancy (TCO) with absolutely zero customer supply-chain disruption. Complete de-rigging, cross-country logistics, and validation managed entirely by DPS.

Successful Execution Sequence: Feb 1 – Apr 8, 2025
Live Production
Golden West Food Group Processing Room Integration and Packaging Line
Duration
10 Weeks
USDA • SQF • BRC First-Pass
100% compliant sanitary zoning design
National Logistics
Co-packing distribution coverage across 50 States + Canada
Zero Supply Gap
Production preserved with continuous customer distribution
Total Fast-Track
End-to-end design-build scope validation

Delivered on Time. Delivered on Promise.

$
18 M
USD Total Investment
Total facility capital evaluation including mechanical integration.
10 Wks
Permit to TCO
Aggressive, double-shifted execution path from groundbreaking to closeout.
100 %
USDA First-Pass Approval
Passed all food safety compliance and regulatory parameters instantly.
0
0 Gaps
Supply Disruptions
Zero commercial distribution or store-level delivery incidents reported.

The Challenge: Transitioning Multi-State Co-Packing Facilities without Operational Disruption

Golden West Food Group required a complete relocation of their active value-added food processing and co-packing operation from Los Angeles to a new facility in Fort Worth under high-density commercial deadlines.

Any physical gap during the cross-country dismantle, rigging, transportation, installation, and final clean-in-place sanitary validation phase would result in missed retail deliveries and damage corporate client agreements.

! Key Pain Points
  • Extremely Compressed Window — 10 physical weeks from plan-permit approval to dry run testing.
  • Simultaneous System Setup — Constructing utility, sanitary plumbing, and electrical lines concurrently with physical build.
  • Zero Tolerance on Retail Delivery — Supply chains had to stay open continuously with no product lag on shelves.
  • First-Pass Regulations — Strict USDA, SQF, BRC criteria validation mandatory.
Scope Responsibility

DPS took complete turnkey responsibility for building permissions, utility systems layout, machinery relocation sequencing from LA, on-site mechanical alignment, and total process validation.

Design • Build • Manage – Executed Flawlessly

D
Stage One

DESIGN

Detailed process engineering, utility planning, and regulatory strategy developed in parallel with the client’s commercial goals. Every system was optimized for speed and future scalability.

B
Stage Two

BUILD

DPS acted as the single point of accountability — managing all civil, mechanical, electrical, and process contractors while simultaneously coordinating the cross-country equipment move.

M
Stage Three

MANAGE

Real-time project controls, daily stand-ups, and proactive risk mitigation ensured the project stayed on the critical path. Every decision prioritized both schedule and long-term operational excellence.

CHRONOLOGICAL TIMELINE

10 Weeks of Precision Execution

February 1 — April 8, 2025
Week 0

Permit & Mobilization

Building permit secured Feb 1. Full design-build force mobilized, material staging grids established inside the Fort Worth facility.

Weeks 1–4

Site & Utilities Setup

Civil structural edits, sanitary drains, and robust process water, mechanical steam, and air lines constructed in parallel.

Weeks 4–7

Machine Relocation

Dismantling cooking and packing segments in LA and shipping across regions. Relocated components positioned and leveled on-site.

Weeks 7–9

Validation

Underfloor pipe insulation check, control terminations, SCADA controls dry run, temperature mapping, and Clean-In-Place validations completed.

Week 10 🎉

TCO & Go-Live

Temporary Certificate of Occupancy granted April 8. First official production runs completed with zero material waste or customer delay.

Core Facility Buildout Details

Vertical wall partitions structural assembly phase
Steam pipes network layout over main processing bays
Ventilation and temperature testing grid modules
Detailed control panel terminations loop controls closet
Active clean room machinery lines assembly detail
Concrete trenches and underfloor sanitation elements
Wall piping distributions overview panel
Process plant clean air ducts setup
Stainless automated conveyors positioning stage
Cement works and steel trench channels setup
Heavy utility installations inside main factory closet
Case 1 Fort Worth Facility Buildout 5 img 1
CLIENT VOICE
“DPS didn’t just build a facility — they engineered a solution that kept every customer supplied while we moved our entire operation across the country in record time. Zero delivery defaults.”
MT
Michael Torres VP of Operations, Golden West Food Group
Impact Highlights
Uptime during relocation 100%
Customer retention rate 100%
Time Saved vs. Standard Path 6–8 Mo.

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