The Solution

DuPont Danisco partnered with RMR Process to design and implement a state-of-the-art powder blending facility. RMR Process was selected after a thorough evaluation of various food specialty design and construct companies, as they were found to be "closest to the high standards" DuPont Danisco was seeking to achieve.

The solution delivered by RMR Process included:

  1. Specialized Facility Design: A three-story, highly specialized, high-care powder blending facility

  2. Innovative Construction Approach: Building the new facility inside an existing operational warehouse at Erskine Park, Sydney

  3. Process Optimization: Redesigning manufacturing workflows for maximum efficiency within a smaller footprint

  4. High-Care Environment: Implementing advanced food safety systems to exceed regulatory requirements

  5. Project Management Excellence: Overseeing the entire project from design through execution to start-up

Case Study:

DuPont Danisco

The Challenge

DuPont Danisco, a global food ingredients company, faced significant operational constraints that were limiting their business growth:

  1. Facility Limitations: Their existing Banksmeadow facility in Sydney's south had been outgrown and could no longer support their production needs

  2. Volume Constraints: The company needed to achieve higher production volumes to meet market demand

  3. Food Safety Requirements: Increasingly stringent food safety standards were becoming difficult to meet in their aging facility

  4. Operational Efficiency: The existing facility had an unnecessarily large footprint with inefficient processes

  5. Market Adaptability: Limited capability to handle a wider scope of ingredients restricted their ability to enter new markets

These challenges were hindering DuPont Danisco's ability to grow and adapt to changing market conditions, potentially threatening their competitive position in the food ingredients sector.

The Results

The partnership with RMR Process delivered transformative outcomes for DuPont Danisco:

  • Footprint Reduction: Achieved a 60% reduction in facility footprint while maintaining a similar manufacturing process

  • Increased Throughput: Realized a 27% increase in throughput per hour

  • Resource Efficiency: Dramatically reduced energy and water use per kilogram of product

  • Market Expansion: Gained capability to handle a wider scope of ingredients, opening up new market opportunities

  • Operational Agility: Became more flexible and agile as a manufacturer, better positioned to adapt to changing market needs

  • Enhanced Safety: Created a facility that is easier to manage from a safety and serviceability perspective

Key Takeaway

DuPont Danisco's experience demonstrates how strategic facility design and process optimization can transform manufacturing capabilities, enabling significant business growth while simultaneously reducing operational footprint and resource consumption.

"We connected with various food specialty design and construct companies, viewed all their finished works and found RMR to be closest to the high standards we were seeking to achieve." - Glen Robson, Manufacturing and SHE Leader, Danisco Australia