• Packaging Expansion
• FEL-2 Study
• Budgetary Cost Development
• Scope Development
• Budget: $3-5 MM

Project Overview

In 2024, IFE was engaged to conduct an FEL-2 study to assess the viability of expanding an existing packaging line to support increased production capacity. This expansion aimed to address growing demand for capacity through the addition of a new packaging line (“pack string”), which would include a new frozen product distribution system, multi-head scale, vertical form-fill-and-seal bagger, QA/QC equipment , and cartoner.

Scope of Work and Project Execution

IFE provided a comprehensive FEL-2 design package, including a cost estimate, for the client’s payback analysis. The budget was developed in coordination with the client’s preferred equipment vendors, who provided cost estimates for over 90% of the required equipment. Additionally, IFE developed both mechanical and electrical installation scopes of work to get estimates from installation contractors, facilitating accurate budgetary costs for the installation.

The study revealed that the existing building space was insufficient to accommodate the required equipment due to higher than acceptable safety risks in managing people and food safety. Following a detailed risk assessment, the client decided to incorporate this capacity increase into a potential building expansion as part of their CapEx master planning for the future.

To address spatial constraints, IFE also provided cost options for increasing the speed of the existing VFFS bagger without adding a new packaging line. IFE worked with equipment vendors to present this alternative, enabling the client to consider a less costly option that could meet increased packaging needs within the existing . The deliverables were used by the client to prioritize this improvement, and it was entered into their long-term capital plan.

Outcome

IFE’s final deliverables for the FEL-2 phase included:

• A 30% General Arrangement (GA) layout with critical elevations.
• A 30% master utility matrix for additional equipment.
• An overall project cost estimate with a +20% contingency.

This FEL-2 package equipped the client with options to meet current production demands and consider strategic facility expansion in the future.