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4104 BE Culemborg
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Masterplan Concept Engineering & Expansion processing & new factory Dapp

Mas­ter­plan Con­cept En­gi­neer­ing & Ex­pan­sion pro­cess­ing & new fac­to­ry

Our cus­tomer is a tra­di­tion­al pro­duc­er of fresh yo­gurt and drinks for the re­tail mar­ket. The com­pa­ny has grown over the years from a dairy farm to the pro­fes­sion­al milk and cream pro­ces­sor it is today.

A few years ago, the need arose for a mas­ter plan to phase out and re­place ob­so­lete equip­ment in a planned and struc­tured way and there­by pre­pare for the am­bi­tious growth plans that the com­pa­ny had for­mu­lat­ed. This year (2018) DAPP was asked to shape the Mas­ter Plan. The first step was to work out the con­cept en­gi­neer­ing in its en­tire­ty.

Due to the ver­sa­til­i­ty of the cus­tomer de­mand, DAPP has ap­proached this project as a  mul­ti­dis­ci­plinary project. This meant that we in­te­grat­ed a num­ber of ac­tiv­i­ties and per­formed them side by side. This con­cerns, among other things, the re­de­vel­op­ment of the site, the de­vel­op­ment of a new pro­duc­tion hall to be built with the as­so­ci­at­ed tech­nol­o­gy. At the same time the re­place­ment of var­i­ous pro­cess­ing equip­ment such as a blender, the shear mixer, the Clean­ing in Place in­stal­la­tion (the CIP) and the chillers. Also, as part of the changes, a pal­let con­vey­or track was pur­chased and in­stalled in one of the cold stores. The lat­ter meant that the lo­gis­tics routes had to be re­de­fined, which was also taken care of by DAPP. Fi­nal­ly, DAPP su­per­vised the en­tire process from draw­ings to ob­tain­ing the nec­es­sary per­mits.

With the de­liv­ery of the Mas­ter Plan, there was such a clear and un­am­bigu­ous def­i­ni­tion of the fol­low-up that the cus­tomer had full con­fi­dence to go fur­ther into the project with its own team of em­ploy­ees and to im­ple­ment it in phas­es. DAPP re­ceived many thanks for the ser­vices ren­dered and for its cost-ef­fec­tive ap­proach.

 Dairy

more projects

Layout design and visualization new dairy factory Dapp

Lay­out de­sign and vi­su­al­iza­tion new dairy fac­to­ry

A major play­er in the dairy mar­ket ap­proached us with plans for a brand new dairy plant. In this new state-of-the-art plant, tech­nol­o­gy, lo­gis­tics and or­ga­ni­za­tion will reach the high­est level imag­in­able. Our client knows that this ef­fi­cient dairy plant will add great value for its re­tail cus­tomers, who will ben­e­fit from a wider prod­uct range and a cost ad­van­tage. The dairy pro­duc­er would like to con­vince its re­tail cus­tomers of this added value with a vi­su­al­iza­tion of the new plant. Dapp was com­mis­sioned to come up with a plan for the de­sired lay­out and to work out the vi­su­al­iza­tion of the new fac­to­ry. One of our ex­pe­ri­enced project man­agers, a spe­cial­ist in ware­hous­ing and sup­ply chain man­age­ment, su­per­vis­es the en­tire project, tak­ing into ac­count the prod­uct and cus­tomer port­fo­lio of the dairy pro­duc­er. In the new plant, not only the pro­duc­tion flows, but also the lo­gis­tics flows must be well con­nect­ed. The same ap­plies to all util­i­ties, such as elec­tric­i­ty, water and air. There must also be a log­i­cal flow through the en­tire plant: from goods re­ceipt to pro­duc­tion and de­liv­ery of the fin­ished prod­uct. Fur­ther­more, suf­fi­cient space must be planned for of­fices, park­ing lots and the load­ing and un­load­ing docks. In ad­di­tion, our cus­tomer con­sid­ers it very im­por­tant that semi-fin­ished and fin­ished prod­ucts move through var­i­ous de­part­ments with dif­fer­ent types of cli­mate con­trol, where prod­ucts must also be able to be repack­aged. The chal­lenge for our project man­ag­er is to en­sure that this busi­ness case is well ex­plained with op­ti­mal vi­su­al­iza­tion: both for the dairy pro­duc­er it­self and for its re­tail cus­tomers. Our project man­ag­er knows how to trans­late the idea into a de­sign with a sin­gle image that says more than a thou­sand words. Our client im­me­di­ate­ly un­der­stands the lay­out of the new dairy and can eas­i­ly con­vince his re­tail cus­tomers of the ben­e­fits and added value. Dairy
Realization of a new building of Refrigerated Warehouse Koningszuivel Dapp

Re­al­iza­tion of a new build­ing of Re­frig­er­at­ed Ware­house Kon­ingszuiv­el

Kon­ings-Zuiv­el has se­lect­ed DAPP to su­per­vise the new con­struc­tion project. Kon­ings-Zuiv­el im­ports dairy prod­ucts from var­i­ous Eu­ro­pean coun­tries and mar­kets them at var­i­ous par­ties in and out­side the Nether­lands. For ex­am­ple, in ad­di­tion to other ac­tiv­i­ties, dairy and other chilled prod­ucts are sup­plied to the large Dutch su­per­mar­kets. Real es­tate de­vel­op­er WDP was com­mis­sioned to build a com­plete­ly new DC of ap­prox­i­mate­ly 10,000 m2 at a lo­ca­tion to be de­vel­oped in Bleiswi­jk near the in­ter­sec­tion of the HSL and the A12. The build­ing was to have re­frig­er­at­ed stor­age and a large dis­patch area. The build­ing should be de­liv­ered in ac­cor­dance with high-qual­i­ty sus­tain­abil­i­ty and en­er­gy re­quire­ments (BREEAM Very Good). The DC has a height of ap­prox­i­mate­ly 12 me­ters (equiv­a­lent to 5 pal­let lay­ers). DAPP has led the en­tire re­al­iza­tion (en­gi­neer­ing, lo­gis­tics in­fra­struc­ture and con­struc­tion + tech­nol­o­gy) with a spe­cial­ist project team. In ad­di­tion to the DAPP project man­ag­er, the team con­sist­ed of spe­cial­ists from DAPP's data­base in the field of qual­i­ty & cer­ti­fi­ca­tion, lo­gis­tics, con­struc­tion, cli­mate tech­nol­o­gy & en­er­gy and elec­tric­i­ty & in­stru­men­ta­tion. Kon­ings-Zuiv­el has out­sourced the en­tire con­struc­tion and de­liv­ery process and has been able to limit its con­tri­bu­tions to the reg­u­lar co­or­di­na­tion of re­quire­ments and wish­es with re­gard to plan­ning and qual­i­ty. In fact, we are talk­ing about a â??turnkeyâ?? so­lu­tion here. Kon­ings-Zuiv­el has moved to a com­plete­ly work­ing new DC. The DAPP project team was able to com­plete­ly un­bur­den the client. Very nice for a client if you can fall back on ex­per­tise that you have never had to deal with your­self. In terms of BREEAM, the build­ing does in­deed meet the ap­pli­ca­ble sus­tain­abil­i­ty re­quire­ments. This also means, for ex­am­ple, that with a BREAAM-NL cer­tifi­cate, Kon­ings-Zuiv­el can achieve a sig­nif­i­cant tax ad­van­tage on the in­vest­ment made. The build­ing is de­signed in such a way that it is scal­able. Should Kon­ings-Zuiv­el grow to such an ex­tent in the com­ing years that the cur­rent fa­cil­i­ty be­comes too small, one of the side walls can eas­i­ly be re­moved to cre­ate a larg­er stor­age space.   Dairy
Redesign Packaging Design Dapp

Re­design Pack­ag­ing De­sign

Our client pro­duces and sells con­sumer prod­ucts such as dairy drinks, in­fant nu­tri­tion, cheese and desserts through its own sub­sidiaries in a large num­ber of Eu­ro­pean coun­tries, in Asia and Africa. With­in the dairy branch of this com­pa­ny, DAPP is ac­tive at var­i­ous cheese pack­ag­ing lo­ca­tions. One of the ap­pli­ca­tions that DAPP was al­lowed to fill in was the sup­ply of a heavy project man­ag­er for the â??Re­design Pack­ag­ingâ?? project. Our client was look­ing for a spe­cial­ist in the field of re­design­ing and re­new­ing the lay­out plan­ning of the var­i­ous pack­ag­ing lines. A phys­i­cal re­lo­ca­tion of these pack­ag­ing lines was also part of the project. This specif­i­cal­ly con­cerned the pack­ag­ing lines for slic­ing, in­ser­tion in ther­mo­form­ing pack­ag­ing, weigh­ing and la­belling, case pack­ing and pal­letiz­ing of var­i­ous types of cheese. Our project man­ag­er has ex­ten­sive ex­pe­ri­ence in re­al­iz­ing com­plex projects in a tech­ni­cal­ly ori­ent­ed en­vi­ron­ment and, more specif­i­cal­ly, in the lay­out de­sign of pack­ag­ing lines. Dur­ing the du­ra­tion of the project, Lars has led a mul­ti­dis­ci­plinary project team. This in­volved mul­ti­ple re­lo­ca­tions and op­ti­miza­tions of ex­ist­ing pack­ag­ing lines. The re­lo­ca­tions re­quired in­ten­sive plan­ning and co­or­di­na­tion be­cause down­time was im­pos­si­ble: pro­duc­tion had to be able to con­tin­ue.   In ad­di­tion to the re­lo­ca­tion of var­i­ous lines, the project also in­volved the de­sign of new ma­chines and sys­tems for case pack­ing and pal­letiz­ing. This de­sign process was guid­ed from de­sign to re­al­iza­tion using the well-known V-Model. Be­fore de­liv­ery, an ex­ten­sive val­i­da­tion pro­gram was com­plet­ed. With a lead time of ap­prox­i­mate­ly 2 years, the project team was able to de­liv­er the project in ac­cor­dance with plan­ning, safe­ty, bud­get and qual­i­ty. Both our client, Lars Goedge­bu­ure and DAPP look back on a won­der­ful­ly chal­leng­ing and suc­cess­ful project. Here too it has be­come clear: DAPP re­al­izes! Dairy
Professional drawing and drawing management increases the clout of a cheese producer Dapp

Pro­fes­sion­al draw­ing and draw­ing man­age­ment in­creas­es the clout of a cheese pro­duc­er

A cheese pro­duc­er asked Dapp if we could sup­ply a good ex­pe­ri­enced pro­fes­sion­al with knowl­edge of Au­to­CAD2 who could con­trib­ute to the ex­e­cu­tion of all kinds of draw­ing work. Dapp then searched its net­work for a per­son with the re­quest­ed knowl­edge and ex­pe­ri­ence. Our pro­fes­sion­al works with Au­to­CAD and In­ven­tor both from home and on lo­ca­tion at the client and is con­nect­ed to the de­part­ment En­gi­neer­ing/Projects. In this de­part­ment, in the first place 2D (Au­to­CAD) or 3D (In­ven­tor) draw­ings are made for projects to be car­ried out. As a sec­ond, no less im­por­tant task she keeps the draw­ings up to date and where nec­es­sary she up­dates the in­for­ma­tion on the draw­ings. This means clean­ing up, up­dat­ing and doc­u­ment­ing the draw­ing file, the P&ID di­a­grams, but also things like the total lay­out of the plant or spe­cif­ic as­sign­ments such as the de­sign of es­cape routes and as­so­ci­at­ed draw­ings.  In con­crete terms, this means that draw­ings or sketch­es are pro­vid­ed by the client(s) which are pro­cessed by our drafts­man in ex­ist­ing draw­ings or, in the case of major changes, a new draw­ing is cre­at­ed and stored as a newer ver­sion in the draw­ings file. It hap­pens reg­u­lar­ly that our draughts­man looks at the sit­u­a­tion on site, mea­sures the lo­ca­tion to en­sure that ev­ery­thing is cor­rect on the draw­ings. It will not be sur­pris­ing that the drafts­man usu­al­ly works alone, but there is much con­sul­ta­tion and co­or­di­na­tion with the client about the final re­sult. The ar­rival of this pro­fes­sion­al drafts­man has led to a much bet­ter or­ga­nized and there­fore much more ac­ces­si­ble draw­ing file. The cus­tomer no­tices the dif­fer­ence. Since her in­volve­ment, draw­ings are found much faster than be­fore. Be­cause changes are pro­cessed im­me­di­ate­ly, draw­ings are al­ways up-to-date and there­fore have a high de­gree of re­li­a­bil­i­ty. They show how cer­tain things are made or de­signed. So no nasty sur­pris­es. In ad­di­tion, some­times the ques­tion is asked to de­sign some­thing in 3D. That is no prob­lem for our pro­fes­sion­al. With In­ven­tor she can draw in 3D. It may be a part that needs to be in stock or a pro­to­type that needs to be de­liv­ered to a ma­chine builder. Such a pro­to­type is then drawn in 3D, after which a pro­duc­tion draw­ing is made. Dairy
Engineering & Project Management Leakage CIP Installation Dairy Company Dapp

En­gi­neer­ing & Project Man­age­ment Leak­age CIP In­stal­la­tion Dairy Com­pa­ny

(*pho­to is not cur­rent sit­u­a­tion). Our cus­tomer had been hav­ing a prob­lem with his CIP (Clean­ing In Place) in­stal­la­tion for some time now. The in­stal­la­tion leaked di­lut­ed caus­tic soda and ni­tric acid due to a mal­func­tion­ing valve. The prob­lem was ex­ac­er­bat­ed by foam to which the level de­tec­tor was not re­spond­ing. For ex­am­ple, it could hap­pen that CIP liq­uid from a tank over­flowed the floor. In this case, the prob­lem owner was the plant man­ag­er and, be­cause the CIP in­stal­la­tion in the pre-plant is an in­stal­la­tion that is used daily, he want­ed to have that prob­lem solved per­ma­nent­ly. An ex­ter­nal project lead­er was ap­point­ed via DAPP. Our project lead­er im­me­di­ate­ly start­ed mak­ing an in­ven­to­ry of the prob­lem and the re­sult­ing risks. The CIP in­stal­la­tion turned out to be on a mez­za­nine floor, above the pro­duc­tion. This meant that solv­ing this prob­lem, es­pe­cial­ly in the prepa­ra­tion phase, re­quired a lot of at­ten­tion for the ar­chi­tec­tural side of the as­sign­ment. The mez­za­nine floor of the CIP in­stal­la­tion had a mem­brane in the floor and this was leak­ing in a num­ber of places. As a re­sult, a dan­ger­ous sit­u­a­tion could arise on the ground floor. This led, among other things, to ar­chi­tec­tural fail­ures: fall­ing stuc­co and tiles and the crum­bling of con­crete lin­tels. This nat­u­ral­ly had a major im­pact on the gen­er­al hy­giene in this part of the fac­to­ry. This prob­lem was men­tioned sev­er­al times dur­ing au­dits. This nui­sance meant that extra rounds had to be sched­uled for clean­ing and re­peat­ed re­place­ment of stuc­co and tiling. Last but not least, the ex­ist­ing sit­u­a­tion led to the dan­ger of leak­age of lye and acid so­lu­tions down the wall where elec­tri­cal switch boxes were hung. In short, a very un­de­sir­able sit­u­a­tion. The project de­ci­sion is nor­mal­ly com­plet­ed with a busi­ness case or a cost cal­cu­la­tion on the basis of which a go - no go de­ci­sion can be made. That was not the case in this project: the project had to be car­ried out any­way. What mat­tered in­stead was how it was per­formed. The cen­tral ques­tion was how the floor could be made com­plete­ly liq­uid-tight. After the in­ven­to­ry of all al­ter­na­tives, it was de­cid­ed to â??liftâ? the CIP in­stal­la­tion con­sist­ing of 4 tanks and place it in a metal drip tray. Our project man­ag­er had to take a num­ber of pre­con­di­tions into ac­count. For ex­am­ple, in ad­di­tion to ar­chi­tec­tural as­pects, safe­ty risks, pro­duc­tion down­time and fu­ture ex­pan­sions in this zone of the fac­to­ry had to be taken into ac­count. In this phase he ex­plic­it­ly in­volved the QHSE de­part­ment in plan­ning. The choic­es made in the project had to be able to count on the full sup­port of that de­part­ment. In the project prepa­ra­tion phase, our project lead­er and his 4 project em­ploy­ees worked with the Early Equip­ment Man­age­ment (EEM) method. This work­flow sys­tem con­tains all man­age­ment as­pects that are nec­es­sary to en­gi­neer a project. If han­dled prop­er­ly, it en­sures a ver­ti­cal start-up and a rapid com­ple­tion of the project. It rais­es ques­tions such as which ma­te­ri­als are re­sis­tant to the ac­tion of ni­tric acid and caus­tic soda. An ar­chi­tec­tural chal­lenge turned out to be the extra sup­port of the roof con­struc­tion nec­es­sary to be able to lift the tanks dur­ing the project ex­e­cu­tion. The re­sult of the project is a liq­uid-tight floor and a leak-free CIP in­stal­la­tion, cre­at­ing a sus­tain­ably safe en­vi­ron­ment for the em­ploy­ees and for the in­stal­la­tion it­self on the first floor and on the ground floor. The plant man­ag­er was ex­treme­ly pleased that the project had fi­nal­ly put a stop to a re­cur­ring prob­lem. It was nice that the project could be com­plet­ed with­in the pre-al­lo­cat­ed bud­get. The QHSE de­part­ment was also very sat­is­fied. The project passed their strict re­quire­ments with fly­ing col­ors. Dairy
Facility Layout Solution at a cheese processor Dapp

Fa­cil­i­ty Lay­out So­lu­tion at a cheese pro­ces­sor

For a cheese pro­ces­sor in the Hoogeveen re­gion, Dapp car­ried out a Fa­cil­i­ty Lay­out So­lu­tion (FLS) in a few weeks. The as­sign­ment was to iden­ti­fy and quan­ti­fy ex­ist­ing and fu­ture re­quire­ments. By draw­ing up the nec­es­sary data sheets in col­lab­o­ra­tion with the client, an FLS model could be cre­at­ed that served as a basis for even­tu­al­ly work­ing out a num­ber of op­tions for the ex­pan­sion and re­design of the fac­to­ry. By using the FLS model, the best op­tion that suit­ed the cus­tomer's needs could be cho­sen in order to min­i­mize the ma­te­ri­al han­dling costs. For this pur­pose, in ad­di­tion to 2D im­ages, 3D im­ages were also cre­at­ed. Dairy
Combining 3 cheese processing factories at 1 site Dapp

Com­bin­ing 3 cheese pro­cess­ing fac­to­ries at 1 site

For a cheese pro­ces­sor in the Utrecht re­gion, Dapp con­trib­uted to the de­sign of an ex­ist­ing build­ing where 3 dif­fer­ent cheese pro­cess­ing plants had to be merged. Be­cause the ex­ist­ing build­ing had quite a few re­stric­tions, it was dif­fi­cult to see a good so­lu­tion due to the many dif­fer­ent pro­cess­es and flows. By means of the Fa­cil­i­ty Lay­out So­lu­tion model (FLS) it be­came clear which di­rec­tions and lay­outs would yield a fa­vor­able lay­out in both prac­ti­cal ob­jec­tions and ma­te­ri­al han­dling costs. An it­er­a­tive process be­tween the client, Dapp and the model en­sured that the model con­tin­ued to evolve and pro­vide a so­lu­tion that served as the basis for the final so­lu­tion. Dairy
Managing drawings at a cheese processor Dapp

Man­ag­ing draw­ings at a cheese pro­ces­sor

For a cheese pro­ces­sor in the Be­tuwe, Dapp helped with the draw­ings and their man­age­ment for a longer and still on­go­ing pe­ri­od. Dapp merged ex­ist­ing draw­ings into a so-called 'mas­ter file' where­by var­i­ous as­pects of the draw­ings could be eas­i­ly shared and ad­just­ed with­out hav­ing to turn the en­tire draw­ing pack­age up­side down or shar­ing in­for­ma­tion that was not in­tend­ed for third par­ties. In con­sul­ta­tion with the client's project man­agers, project draw­ings were also made on sev­er­al oc­ca­sions, dur­ing which they were ex­am­ined and mea­sured in the field. In ad­di­tion, Dapp also pro­vid­ed a 3D scan and mea­sured some ex­ist­ing items and up­dat­ed them in the mas­ter file. Dairy
Dapp, Pascalweg 5-06
4104 BE Culemborg, The Netherlands
Telephone: +31(0)345 50 52 56
Email-address: [email protected]
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