Project Extra Chunk is the name given to the expansion of the Saint Albans manufacturing plant of Ben and Jerry’s, the iconic ice cream company founded in 1978 in Burlington, Vermont. This plant, already responsible for two thirds of worldwide production was operating 24/7 so expansion was clearly a must. That around the clock production also was the greatest challenge. How to increase the size of many departments like warehousing, packing, refrigeration areas and mixing rooms all at once without interrupting ongoing operations was the goal!

Project Extra Chunk had a $14,000,000 budget to add 40,0000 square feet of plant space. One of the targets was to minimize on site work to minimize production disruption. Of course, all the expected strict standards related to food safety also applied like at any other food processing plant.

Food refrigeration also brings corrosion concerns due to condensation and humidity build up, especially at the periphery of chilled and ambient air. Rigorous and regular cleaning programs also introduce repeated moisture and harsh antiseptic chemicals. Hot-Dip Galvanizing brought its wide and time-tested value equation to the planning process and was widely applied wherever corrosion was a concern.

Proven long-term performance in other refrigerated food plants nearby made it clear that Hot-Dip was the right solution for building life. It’s rugged impact resistant surface insured rapid erection without the typical time consuming and questionable effectiveness of touch-ups on paint-based systems.

Thanks in part to Hot-Dip Project Extra Chunk was a success with budgets and schedules all met or bettered. The Ben and Jerry’s Saint Albans plant is now operating with 65 more employees and cranking out 20 percent more of those delicious pints of Ice Cream in a myriad of funky flavors!