In Saskatoon, Saskatchewan, Scott Builders partnered with Saputo Food and Excel Engineering to achieve a complex goal: expanding a major food-processing plant without interrupting its operations.
The Saputo project demonstrates how collaborative planning, technical innovation, and rigorous safety measures can overcome the challenges of building in a live production environment. Completed in 2020, the dairy plant expansion was finished on schedule and within budget, underscoring Scott Builders’ commitment to quality, reliability, and client success.
Zero Downtime, On-Budget Delivery in a Fully Operational Plant
- Scope & Delivery: 30,000 sq. ft. addition to an active dairy processing facility, delivered under a CCDC 5B Construction Management at Risk contract in collaboration with Excel Engineering
- Schedule & Budget: Construction spanned 24 months (August 2018 – August 2020) and was completed on time. The project met its budget, with a final cost of $27M.
- Key Challenges: Expanding within a fully operational food plant demanded strict contamination control and careful phasing to avoid any downtime.
- Outcome: A successful, food-safe expansion that increased Saputo’s production capacity while keeping the existing plant running continuously, with the project delivered on time and on budget.
A Strategic Expansion to Support Increased Dairy Production
Scott Builders served as construction manager for this major expansion to Saputo’s dairy processing plant in Saskatoon. The 30,000 sq. ft. addition to create a new cheese processing line.
The project also included select renovations to tie the new construction into Saputo’s ongoing operations. Working under a CCDC 5B Construction Management at Risk contract, Scott Builders’ team coordinated closely with the design consultant, Excel Engineering, to plan every detail for seamless execution. This created three specialized areas: a new dry goods storage warehouse, a state-of-the-art refrigerated cheese cooler, and a dedicated case wash facility, all integrated into the existing plant.
The expansion’s precast concrete structural system was chosen for its quality and speed of erection, minimizing on-site construction time. This approach, along with advanced scheduling, allowed most heavy work to occur externally or during planned outages, limiting the impact on plant activities.
From robust refrigeration systems in the cheese cooler to sanitary drainage in the wash bay, each element of the design was executed to meet strict food-industry standards and to align with Saputo’s production needs.
Project at a Glance
- Delivery Method: CCDC 5B Construction Management at Risk
- Timeline: 24 months, August 2018 to August 2020
- Budget: $27M
- Construction: Precast concrete structure with structural steel framing
- Team: Eric Weisse (Project Manager), Wes Baranieski (Site Superintendent)
Strict Food Safety, Live Operations, and Complex Tie-Ins
- Live Operations: The facility had to remain fully operational throughout construction, allowing no unplanned shutdowns.
- Food Safety: Strict hygiene standards required preventing dust, debris, or contaminants from affecting ongoing dairy production.
- Complex Tie-Ins: New systems (refrigeration, mechanical, electrical) needed to integrate with existing production lines without disruption.
Isolated Work Zones, Precast Speed, and Close Coordination
- Containment Measures: Built temporary dust-tight partitions, negative-air pressure zones, and specialized ventilation to isolate construction areas and protect product quality.
- Off-Peak Scheduling: Performed major tie-ins and heavy construction during off-peak hours or scheduled maintenance windows, ensuring production remained on track.
- Precast Speed: Utilized precast concrete panels for the structure to accelerate construction and reduce the on-site work window.
- Close Coordination: Held frequent coordination meetings with Saputo’s plant staff and Excel Engineering to align construction activities with production schedules and quickly address any issues.
- Quality Control: Enforced rigorous cleaning protocols and regular inspections so that food safety was never compromised.
“This expansion was all about teamwork and precision,” says Eric Weisse, Project Manager. “Our team worked hand-in-hand with Saputo’s staff and Excel Engineering to keep cheese production running smoothly while we built a top-notch facility on schedule and on budget.”
Safe, Efficient Growth Without Skipping a Beat
- On-Time Completion: Finished the addition and renovation by August 2020 as planned, enabling Saputo to begin using the new facilities immediately.
- On Budget Delivery: Delivered at the budgeted $27M, with careful cost management to ensure no overruns.
- Zero Downtime: Plant operations continued without interruption, recording zero unplanned downtime during construction.
Safe & Clean Construction: Maintained strict food-safe conditions throughout, with no contamination incidents or safety compromises despite the active environment.
- Enhanced Capacity: The 30,000 sq. ft. expansion significantly increased Saputo’s storage and processing capacity, allowing greater production volume and efficiency.
- Stakeholder Satisfaction: Saputo (the client) and Excel Engineering praised the project’s seamless execution and transparent communication.
- Community Impact: By expanding local production capabilities, the project helped secure jobs and support Saskatchewan’s dairy producers, reinforcing Saputo’s investment in the region.
Seamless Expansion, Delivered Through True Partnership
The Saputo Saskatoon expansion highlights Scott Builders’ expertise in delivering complex industrial projects under live operating conditions. Through meticulous planning, innovative execution, and close collaboration with the client and consultant, the team delivered a critical facility upgrade without disrupting operations.
This project reinforces Scott Builders’ reputation for solving tough construction management challenges with precision, partnership, and an unwavering focus on quality and safety.
Call to Action: Let’s Build Your Vision
Having the right food processing facility construction partner is crucial when facing operational challenges. If you’re planning a build or expansion and need a builder who will collaborate closely, solve problems proactively, and deliver a high-quality facility on schedule, Scott Builders is ready to help.
Contact us today to discuss how our team can bring your vision to life with the same commitment, expertise, and care.