This expanded facility delivers extended shelf-life products with efficiency and sustainability in mind.
As consumer demand for extended shelf-life (ESL) dairy and non-dairy beverages surged across the East Coast, HP Hood set out to expand its capabilities and strengthen long-term supply. The company’s Winchester, Virginia, facility grew from 265,000 square feet to 441,000 square feet, creating a state-of-the-art processing hub equipped to deliver safe, high-quality products with superior shelf stability.
Our integrated team provided a totally turnkey solution that streamlined operations and maintained sanitary compliance.
Haskell provided turnkey solutions, from process engineering, packaging engineering, electrical engineering, programming and controls, equipment installation and start-up and commissioning services to ensure streamlined operations while maintaining compliance with sanitary regulations. The project included the demolition of an old filler and subsequent installation of the new aseptic filler, modernization of the packaging line of the new filler, decoupling palletizers, upgrades to the CIP system, expansion of the processing room, installation of five new silos, transfer panels and valve skids, as well as an expansion to the refrigerated 100-foot-tall Automated Storage and Retrieval System (ASRS). Haskell provided integrated design and construction, as well as self-performed millwright services and sanitary piping installation services.
A highly integrated process control system maintains precise monitoring and communication across all operating components. This automation enhances production efficiency, improves food safety, minimizes downtime and reduces product loss, enabling the client to meet escalating market demand with confidence.
The facility improved sustainability today with an eye toward future adaptability and expansion.
Sanitary design and automation improvements reduced water and chemical use during CIP operations without compromising product integrity. Optimized batching and system interlocks further decreased waste, energy demand and operating costs. The result is a scalable, responsible ESL facility that protects resources while delivering reliable output.
By combining advanced technology, optimized workflows and sustainable practices, HP Hood now operates one of the East Coast’s leading ESL production facilities. It is equipped to adapt, expand, and continue meeting consumer and retailer expectations for safe, long-lasting beverages.
