A repeat BWS client needed to expand the facility Haskell originally built.

Haskell built a greenfield manufacturing facility for Gallo in Fort Lawn, and the two partnered again to add a new spirits bottling and processing line that would enable Gallo to pursue emerging market opportunities while maintaining uninterrupted operations within an active production facility. Haskell executed engineering, procurement and construction (EPC) services 57 days ahead of schedule, working more than 100,000 work hours without a recordable incident.

Gallo sought to integrate a high-speed flask bottling line and expand brandy processing capabilities.

To support the new product platform, Haskell designed and installed a custom integrated PET packaging line capable of operating at 500 bottles per minute across 100 mL, 200 mL and 375 mL formats. Its Automated Manufacturing Systems specialists upgraded process systems, facility infrastructure, utilities, automation and controls. New process vessels, interconnecting piping and automation integration equip the facility for 24/7 operation.

Navigating an online facility requires strategic planning and client buy-in.

Working within an operational facility required detailed logistics planning, phased tie-ins and carefully managed shutdowns, all of which risked disrupting existing production lines. Startup planning began months early to map contingencies, assess risks and plan corrective actions. Unified communication with the client captured their quality and safety goals and ensured a coordinated startup. Working on equipment tie-ins during limited time windows when machinery was already offline shortened shutdowns as much as possible.

Haskell’s multi-disciplinary team mitigated unplanned challenges.

Cortez, a Haskell Company, brings decades of expertise in fabricating, installing and maintaining process packaging and piping for food production systems. When the client faced issues securing timely funding, Cortez developed a solution that divided the project scope and accelerated the schedule. By mitigating delays, the project avoided additional change orders.

Gallo’s newest project builds on a trusted partnership.

A combination of process expertise, packaging engineering, facility design-build and construction management helped Gallo bring a new product platform to market faster.