W.E. Carlson—Modular Wall System Offers Flexibility, Energy Savings

W.E. Carlson Offers Clean Solution
to Flexible Packaging Company’s
Inside Loading Dock Dilemma

Situation

Floeter, Inc., an international flexible packaging company located in Elk Grove Village, Illinois, creates containers—more than 1.2 billion units a year—for manufacturers ranging from pet food to candy. Because the packaging may involve product for pet or human consumption, there are strict industry processing standards to which Floeter must adhere. Plus, the machines that assemble the packaging give off a high level of heat, so the facility needs to be air conditioned to maintain the expensive equipment and keep employees comfortable.

To meet the increasing demand for its new flexible packaging, a state-of-the-art machine was purchased and was being delivered sooner than expected. The only logical space for the new equipment was in an area of the facility open to the inside loading dock, where the raw materials are brought in for production, and the finished product is moved out. That outside door was opened up to 20 times a day, letting insects and dust in, and costly temperature-controlled air out.

BEFORE

In that environment, passing a food industry audit would be next to impossible. And if they didn’t pass inspection? A shut-down would cost Floeter a whopping $40,000 - $45,000 per machine, per shift, in lost production.

Challenge

Floeter Inc., needed to separate the inside dock from the new production area to retain control of environment and temperature without undergoing a dirty, dusty construction project that would infiltrate—and ultimately shut down—the production process.

Solution

Constructing a traditional wall was not an option; the dirt and dust generated would contaminate the production area. Instead, W.E. Carlson recommended installing a modular wall system. Together with PortaFab, a manufacturer of modular building systems, W.E. Carlson created a floor-to-ceiling modular wall built entirely from insulated, prefabricated panels. These panels can be reconfigured if necessary, and unlike traditional construction projects, may qualify for accelerated depreciation come tax time.

In addition to the new modular wall system, W.E. Carlson installed a high speed door, further limiting the chance of pest or dust infiltration and energy loss, as well as a new ground-to-dock ramp to improve fork lift driver ability to move raw products and finished materials between facilities.

Results

AFTER

Floeter, Inc. can assemble more flexible packaging than ever before, at the highest industry sanitation standards. And because the area is sealed off from exterior conditions, Steve Gallis, General Manager, hopes to save money on heating and air-conditioning, keeping his machines running and employees comfortable for less next year. “The system worked out really well, and we passed our food-industry audit with flying colors,” said Gallis. “I’d recommend a modular wall system to anyone looking for flexibility and insulation.”

Equipment Installed
PortaFab Modular Wall System
FasTrax High Speed Door
Wayne Dalton Sectional Door
Ground-to-Dock Ramp

For More Information
Dan Dumelle, 847.640.0011
ddumelle@wecarlson.com