Completed Projects
Alef Sausage Co. Addition, Mundelein, IL
This was the third major project we have worked on with Alef Sausage Company. Having been the driving force for the initial buildout of an existing warehouse in 2005 into a complete sausage processing plant, Alef Sausage once again turned to American Igloo Builders in 2008 for a small addition of 2,500 sq. ft. Within 12 months, Alef Sausage returned again to American Igloo Builders for consultation for expansion ideas. After looking at several properties in the vicinity of the existing facility, Alef Sausage chose the conceptual plans prepared by American Igloo Builders which utilized an adjacent vacant property for expansion of their existing facility.
Construction was completed in July 2011 on a 19,000 sq. ft building addition to an existing 16,000 sq ft sausage manufacturing facility in Mundelein, IL. This design-build general construction project consisted of expansion of existing production and storage facilities by 300%. Special design features included an intricate floor drainage system, smokehouse installation, a centralized Freon refrigeration system, a new electrical service, heavy slabs for grinding equipment, and stainless steel insulated panels and doors in the new production areas.
The design criteria centered on the very common food industry problem of separation of raw and cooked product. With the installation of a new receiving dock and dedicated refuse room for trash and a baler for cardboard, Alef Sausage is able to fully comply with USDA requirements for raw and cooked separation. In addition, a separate welfare area including locker rooms, toilet facilities, and offices were created to maintain the separation between the raw and RTE production employees.
The project presented several challenges upon its inception. An unimproved vacant lot with a number of easement issues and topography conflicts was purchased adjacent to the existing facility. Site improvements included a new depressed dock and expansion of existing parking facilities. In addition to the challenges presented by the site, construction was completed during daily operations of an existing USDA-inspected facility.
Roundy's Commissary, Inc., Kenosha, WI
This design/build project consisted of a new 120,000 square foot state-of-the-art food manufacturing plant constructed on a 12-acre unimproved building site.
