Case Study: BSM Partners Successfully Launches and Optimizes Client’s Human-Grade Baked Kibble Facility from a Repurposed Ingredient Warehouse

The challenge

Designing, implementing, and optimizing a new pet food production facility can be intimidating. There are many moving parts to consider, and staying under budget and on track can prove to be a challenging feat. Recently, a client sought BSM Partners’ Engineering Service’s expertise to oversee the transformation of a previously used ingredient storage space into an efficient human-grade baked kibble production facility. The project objectives were clear:

• Design the plant to ensure safety and efficiency.
• Manage end-to-end construction within specified timelines and budget.
• Implement measures for continuous improvement upon commencement of operations.

The solution

Leveraging our team's extensive industry knowledge and experience, BSM Partners’ Engineering Service offered a turnkey solution, guiding the client through every phase of the project with ease. Additional collaboration from other BSM Partners’ Services - Product Innovation, FSQAR, and Nutrition –in combination with expert process innovation the following process ensured the quality and success of the finished baked kibble:

• Develop multiple layout proposals encompassing utilities, offices, labs, maintenance, and production areas.
• Solicit competitive quotes for essential equipment procurement.
• Establish and set up utility consumption to accommodate current equipment and future expansion needs.
• Provide direction for seamless installation of equipment and integration of controls.
• Facilitate risk assessments, design reviews, and after-action evaluations.
• Conduct rigorous commissioning, validation, and startup procedures.
• Manage procurement processes and financial transactions with contractors and vendors.

The result

The client was able to achieve a successful launch of their human-grade baked kibble within a remarkably condensed timeline of just two years. In an industry where a new plant build can take up to 4 years or even longer, that’s a significant timeline reduction. Furthermore, our post-project collaboration with the client yielded ongoing operational enhancements, enhancing efficiency, and maximizing cost savings.

Highlights

• 50% reduction in project timeline compared to industry standards.
• Comprehensive, end-to-end solution delivery.

BSM Partners

BSM Partners is a leading consulting firm operating in the pet and human food industries. BSM Partners is a collective of professionals across a wide variety of industries, backgrounds, and life experiences. We leverage our shared expertise for our clients and draw on our deep connections in the industry to help you succeed. We are prepared for every challenge your business might face. From product development to replenishment, we have you covered. Our services include research, consumer insights, product innovation, food safety and quality, regulatory, nutrition, veterinary, transformation, operations support, and engineering.

BSM Engineering Process Innovation

If you have a passion for finding creative and innovative ways to grow your business, then we are the team for you. We believe that nothing is impossible.

• Providing clients with the successful delivery of their capital projects
• Project management of greenfield facilities and line additions
• Leading fit-for-purpose equipment selection 
• Executing product and process improvements
• Implementing capacity increase and process optimization

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