Unilever, one of the world’s largest producers of packaged consumer goods, is expanding its ice cream manufacturing facility in Covington, Tennessee. The firm selected Primus Builders to provide design-build services on this 315,000 SF dedicated frozen food distribution facility located adjacent to the existing 815,000 SF production facility (one of the largest ice cream manufacturing plants in the world).
The new distribution facility will be “plant attached,” meaning it will be connected to the existing production facility by a -20°F elevated corridor. Product will make its way from the production facility to a 35°F - 40°F pallet delivery space and then down the elevated corridor to the -20° freezer warehouse. The receiving area in the warehouse will be equipped with computer controlled stacker cranes that will distribute product to its assigned space in the warehouse.
The new building will feature 34 dock doors with vertical dock position, one with regular dock position and two with compactor dock positions.
Unilever is firmly committed to conducting business as a good steward of the environment. This is evidenced by the implementation of the Unilever Sustainable Living Plan (USLP), a program that reduces Unilever’s environmental impact while increasing its positive social impact. On this project, Unilever has set a goal of LEED Silver certification. Primus Design Services, LLC and Primus Builders are working closely with the Unilever team to determine which sustainable components will best serve the goals for the facility while reducing its carbon footprint.
Building Information Modeling (BIM) will be incorporated at project kick off and utilized through construction to improve coordination and maintain the project schedule. Implementing BIM allows the team to identify potential clashes during design and offer solutions before construction begins. This will assist the team in achieving the project’s fast-track schedule.
An initial challenge on the project was the site’s soft, wet soil which proved unsuitable for construction activity. To alleviate the problem, Primus will install a system of piers 27’ into the ground and approximately 6’-9’ apart from each other to squeeze water out of the soil and ensure the site can support the building’s foundation.
