HP Hood: Packaging Line Replacement
One coordinated system in an active dairy facility in Winchester, Virginia.
Haskell delivered the EPC/design-build replacement of the legacy filler and packaging line with a new aseptic filler and integrated packaging system at HP Hood’s Winchester, Virginia, facility. Working within 13,800 square feet in the center of an operating dairy plant, the team relocated equipment originally purchased for another facility, upgraded the room and utilities and coordinated modifications across neighboring lines. A point-cloud scan and comprehensive 3D model reduced clashes and field rework, while phased installation and four independent startup efforts protected ongoing production.
System at a Glance
13,800
square feet
130
96-oz bottles per minute (BPM)
10
months FROM design start to saleable product
3
weeks ahead of target
Client Challenge
- Relocate and integrate equipment originally purchased for another facility.
- Fit fixed equipment into limited floor space and existing infrastructure.
- Modify multiple production lines while minimizing downtime in an operating plant.
- Adapt commissioning activities to product demand and plant priorities.
- Execute the project within an active operating facility without disrupting operations or compromising product safety.
Haskell Solution
- Captured existing conditions with point-cloud scanning and a coordinated 3D model.
- Used a phased installation strategy with four independent startup efforts.
- Integrated packaging equipment, controls, utilities and facility modifications.
- Provided 24-hour startup support, OEM training, spare-parts planning and turnover resources.
- Implemented dust-containment measures (negative-pressure,
temp-walls), controlled access between construction and plant areas and maintained close coordination with Plant Operations.
integrated Design-build Value
Haskell coordinated filler relocation, packaging integration, controls, utilities, facility modifications and four phased startups under one team – protecting active production while achieving first product three weeks ahead of the contractual target.
Process interfaces, packaging, controls and facility systems integrated as one operating platform
Simplified Product Flow
Process + Utilities
Product piping, UV and chemical skids; new steam skid, water loop, compressed air, lighting and power.
Facility Modifications
Slab and underground plumbing work, raised IMP ceiling, panel platform, resinous and dairy brick flooring.
Controls + Data
Haskell integrated the packaging line controls into a coordinated PLC/HMI platform that unified OEM interfaces, accumulation logic, fault recovery, inspection, reject tracking and operator visibility — turning multiple pieces of equipment into one integrated operating system.
Packaging Integration
Haskell engineered the line as an integrated system, coordinating equipment interfaces, accumulation, fault recovery, inspection, reject tracking and controls across multiple OEM packages. The system included the overcapper, labeler, inspection, bottle turner, laner, case packer, palletizer and conveyors for two 96-ounce SKUs at 130 BPM.
Quality + Traceability
Leak, cap, label, date-code and open-case inspection with case-code verification and reject tracking.
Operational Readiness
24-hour technical support, OEM training, spare-parts recommendations and organized maintenance documentation.
Commissioning Strategy
Packaging-line checkout, water runs and non-salable-product testing were aligned with filler startup. Haskell provided 24/7 on-site support for the first two weeks of operation and progressed through 1-hour, 8-hour and three consecutive 8-hour performance tests before handoff.
Performance-test boundary
Site Acceptance Test (SAT) measured performance from filler discharge through palletizer; upstream bottle supply and downstream pallet-conveying disruptions were excluded.
Key Milestones
Mechanical
Completion
4/16
First
Water
4/21
First
Product
4/28
Saleable
Product
5/12
Pass
96.92%
1-hour OEE
Target 90%
Pass
88.38%
8-hour OEE
Target 85%
Pass
84.54% AVG
Three 8-hour shifts
Target 80% each
Three-shift results: 80.91%, 89.50% and 83.20%
Verified Startup Performance
Completion prior to FIRST production
Completion prior to first production
Completion prior to first production
Strongest proof point
Haskell delivered first production three weeks ahead of the contractual target, within budget and with zero recordable incidents, while maintaining hygienic separation and protecting ongoing plant operations.
Business Impact
The replacement provided a faster, more maintainable 96-oz. packaging platform designed to improve reliability, simplify maintenance and support more consistent production.
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