Farmer Brothers commissioned Haskell to help expand its production to 96 million pounds of roasted coffee per year.

After relocating its primary coffee manufacturing from California to Texas, Farmer Brothers enlisted Haskell’s services for an engineering, procurement and construction (EPC) project to expand production at a new facility in the Dallas-Fort Worth area. The project was broken into multiple phases that began with master planning and design before moving into the actual project execution and startup. In all, this new expansion would increase the facility’s production capacity to produce 96 million pounds of roasted coffee per year.

We designed process and packaging systems to take our client from raw materials to packaged products.

Our master plan for consolidating Farmer Brothers’ roasting and packaging into one facility began with receiving areas for the raw materials, in this case, green coffee beans. From there, the process included equipment for unloading, cleaning, blending, roasting, grinding and flavoring the beans before sending them to packaging and palletizing the final product. Storage space was also planned and added to hold the beans prior to roasting. Additional handling systems to collect waste, such as the coffee bean chaff, were also included with the system, as was material-handling equipment designed to move 100 cases per minute from all packaging lines. Each phase was executed successfully, including the completion of startup and commissioning for all of the new systems.

The new systems allow Farmer Brothers to better serve its customers.

With the new process and packaging lines up and running, Farmer Brothers is now able to provide additional production for its client accounts. As business continues to grow, we look forward to our continued partnership.