Jerome & Horner

Case Study: Wine Cork Factory Relocation

The Client

Cork Supply USA, Inc., the leading natural cork supplier in North America, was founded in Northern California in 1981. Their core business is the manufacture of natural cork products for premium wine brands. Cork Supply USA also produces a standard-setting range of bottle-closing products (including capsules, screw caps and other forms of enclosure) as well as customized services and expertise around the world, particularly within the global wine industry.
 

The Project

When Cork Supply USA moved their whole operation into a new Cork Supply facility in Northern California in 2008, Jerome and Horner were there to make sure it went smoothly. We assisted in the successful relocation of the entire facility, overcoming immense logistical challenges, to see the company up and running in their new facility within six weeks.
 

For Jerome and Horner, this project required:

• Design and Installation of (sandblasted, primed and painted) structural steel platforms
• Dust collection systems with equipment and piping for four departments
• Compressed air delivery for the entire facility
• The removal, rigging and installation of all equipment
• Design and installation of a custom work station plus equipment support for the cork washing system
• Redesign of the storage hoppers
• Engineering based on structural drawings from other firms involved in the design and construction of the new plant

Design Build Partners

The expert team from Jerome and Horner, led by Senior Consultant Ed Perrick, worked closely with Barry-Wehmiller Design Group. For over 20 years Barry-Wehmiller has provided “Total Operational Solutions” including feasibility studies, master plans, and design-build projects combined with engineering services.In this project the Barry Wehmiller was responsible for all the process and layout engineering. Jerome and Horner’s role was to deliver a design-build plan for the new structural steel platforms that would seamlessly integrate with Barry Wehmiller’s mechanical engineering plans. Working together, the two companies provided the client with a more user-friendly and productive work flow.

For the Pneumatic Conveyance system, which moves corks through the processing stages using compressed air, Jerome and Horner worked with a system provided by Busada Manufacturing Corporation, who have set the standard for pneumatic conveyor tubing and air delivery tube manufacturing for over 55 years.

Challenge - Solution

Challenge
This was a fast-track project with an extremely tight schedule, leaving no margin for error or delay.

Solution
Using over 30,000 pounds of steel, the steel platforms, designed and built by Jerome and Horner, were sand blasted, primed and painted. The entire process, from design, through fabrication to completed installation was achieved within a record six weeks.

Challenge
The client’s operational processes include sorting, washing, printing, coating, and final packaging of corks. All of these processes had to continue for the duration of the transition from the old facility to the new one. Jerome and Horner had to ensure the client had water, dust collection, compressed air, and access to equipment at both locations during the move.

Solution
Thanks to meticulous planning and the combined experience in our expert team, we were able to provide all the necessary changes to utilities as we moved the equipment. The client was able to make the transition to the new facility without any costly disruptions or delay.

Challenge
There was no margin for error. The structural steel had to meet city, state and federal regulation for operator access. We had to get it right, from start to finish.

Solution
All steel platforms were prefabricated, painted and installed with very little field welding or on-site modification required. We had to be right on target, and we were.

Jerome and Horner – We Finish What We Start

This project was packed with challenges. At Jerome and Horner we thrive on exceeding all expectations. The key is that we are always on our toes with our drawings and our clients. Because of our pre-planning and processes, we were able to give the client a new home in just six weeks. The entire project, from first drawings to completed installation took 16 weeks We took great pride in being able to install them comfortably in an efficient, fully-operational facility with minimal interruption to their production.