Built on a greenfield site in Columbia, Mo., the 315,000-sq-ft Swift Prepared Foods facility produces a variety of dried meats, including salami, pepperoni, prosciutto, pancetta and coppa. Initial processing of raw product occurs in Unit 1. Product is then moved via robotic automated guided vehicles into Unit 2, which is the drying and salting area. Once drying or fermenting processes are complete, the product is moved into Units 3, 4, and 5, which are the ready-to-eat areas. From there, the product is sliced, packaged and shipped.

Other areas of the facility feature a research and development plant and a show kitchen. In addition, Stellar designed and constructed two employee welfare areas on either side of the facility to separate the “raw” side personnel from “ready-to-eat” side personnel. At the main office, there’s a small pilot testing plant for new products and an Italian café-inspired show kitchen for customers.

Photo courtesy of Notley Hawkins

The $149-million two-year project broke ground in April 2021 amid the COVID-19 pandemic. At the beginning of the project, the team saw a shortage of roofing materials, which created challenges with interior construction. Process equipment purchased by the owner was being delivered from overseas, and unpredictable delivery dates caused some delays. Frequent coordination meetings were critical for timely completion of scopes of work. In the end, the team was able to deliver the facility on time in May 2023.

The team took a three-phase approach, which included a BIM coordinator, a quality manager and a commissioning representative. Using BIM helped facilitate subcontractor meetings and real-time progress tracking, minimizing delays and incomplete installations. The integration of pre-functional checklists and site visits enabled timely completion and reduced the number of punch-list items. Additionally, the commissioning representative developed a hybrid quality plan, optimizing construction document reviews and resolving conflicts efficiently.

Photo courtesy of Notley Hawkins

Stellar’s quality control responsibilities spanned from the design phase to project completion and warranty period. For the Swift project, an internal quality representative was assigned early on to establish and manage a hybrid commissioning/quality plan. This plan encompassed the installation of HVAC, utilities and electrical systems from design development to project close-out. The utilization of Procore software facilitated document storage and management throughout each phase.

A notable feature of the project was the incorporation of advanced automation technology into the Italian meats and charcuterie production facility. Collaborative meetings between Stellar and Swift resulted in an energy efficient layout and advanced process equipment design. Automated guided vehicles, gantry robots and conveyor belts were employed to ensure seamless flow and maximize productivity. The increased production capacity and improved operational efficiency will enhance the client’s profitability and competitiveness. Moreover, the integration of advanced materials, such as those used in the facility’s design, sets new industry benchmarks for energy efficiency and sustainability.