Namasco Steel – New Facility

Industrial PORTFOLIO

Namasco Steel – New Facility

Kloeckner Metals (formerly Namasco), Dubuque, IA

SPECIFICATIONS

LOCATION

Dubuque, IA

CLIENT

Conlon Construction Co.

CONTRACT AMOUNT

$500,000

FEATURED

Power and lighting to an outdoor loading dock

Photo Credit: Kloeckner Metals

Namasco is a steel warehouse and fabrication factory that imports, houses, and fabricates all sizes of plate and beam steel. Products are then distributed to manufacturers and other fabricators. Our installation included power, lighting, and voice, data, and video cabling for the warehouse and office areas. We also installed power and lighting to an outdoor loading dock which holds four 50-ton bridge cranes.

GOEX Corporation

Industrial PORTFOLIO

Goex Corporation

GOEX Corporation, Janesville, WI

SPECIFICATIONS

LOCATION

Janesville, WI

SIZE

153,600 SF

CLIENT

GOEX Corporation

CONTRACT AMOUNT

$400,000

FEATURED

3 3000 amp, 480 volt services

This design-build manufacturing project included a 106,000 square-foot manufacturing area, 40,000 square feet of warehouse space, and a 7,600 square-foot, two-story office. Our scope included three 3000 amp, 480 volt services feeding 750 feet of 3000 amp bus duct on the manufacturing floor, and 400 feet of 1200 amp buss duct in a tunnel under the factory floor. The entire facility is illuminated with LED light fixtures using one third of the fixtures required with typical fluorescent lighting.

Jones Dairy Farm – South

Industrial PORTFOLIO

Jones Dairy Farm - South

Jones Dairy, Fort Atkinson, WI

SPECIFICATIONS

LOCATION

Fort Atkinson, WI

SIZE

42,000 SF

CLIENT

Maas Brothers Construction

CONTRACT AMOUNT

$2.7MM

FEATURED

New equipment for full facility

Photo Credit: ESI Group USA

The overall project scope is demolition and build back of a new, 18,000 square-foot production building, as well as demolition and build back of a 24,000 square-foot area in the center of the main building. Additional work includes remodel of almost the entire facility and new equipment such as ovens, cooking equipment, mechanical equipment, and electrical equipment.

Kraft/Oscar Mayer J-Con II Project

Industrial PORTFOLIO

Kraft/Oscar Mayer J-Con II Project

Kraft Foods, Madison, WI

SPECIFICATIONS

LOCATION

Madison, WI

SIZE

97,000 SF

CLIENT

Kraft Foods

CONTRACT AMOUNT

$4.6M

FEATURED

5kV substation to power the new facility

Photo Credit: Findorff

This project consisted of a 97,000 square-foot renovation that converted storage space into a food processing and manufacturing facility. The electrical work included the installation of a 5kV substation to power the new facility, with no downtime for the existing plant. The scope of work also included the installation of stainless steel raceways, new lighting, and power and controls for food processing equipment. The equipment includes industrial ovens, meat grinders, and conveyors.

Swiss Valley Cheese Production Facility

Industrial PORTFOLIO

Swiss Valley Cheese Production Facility

Swiss Valley Farms, Luana, IA

SPECIFICATIONS

LOCATION

Luana, IA

CLIENT

Conlon Construction Co.

CONTRACT AMOUNT

$1.2M

FEATURED

New process equipment connections

Photo Credit: Dairy Foods Magazine

This major remodeling of state-of-the-art production facilities for Swiss Valley’s premiere Swiss cheese factory included new primary electrical service, lighting, low voltage systems, and process equipment connections. All construction was completed at USDA and FDA food production facility standards. Swiss Valley is a leader in the manufacturing of Swiss and Baby Swiss cheese, the most difficult of all cheeses to produce.

General Motors Paint Shop Addition

Industrial PORTFOLIO

General Motors Paint Shop Addition

General Motors Corporation, Lansing, MI

SPECIFICATIONS

LOCATION

Lansing, MI

CLIENT

DACS International, Inc.

CONTRACT AMOUNT

$2.2MM

FEATURED

Pendulum conveyors interlocked with robotic cells

Photo Credit: General Motors

Westphal & Co., Inc. completed installation of a material handling conveyor for the General Motors Paint Shop facility located in Lansing, MI. The plant was built to meet new demand for Cross-Over-Vehicles (CUV’s). The project included skid conveyors, inverted mono-rail conveyors, and pendulum conveyors interlocked with robotic cells, paint booths, ovens, and dip tanks. Field wiring installation for 36 separate conveyor systems was completed, including control devices, motors, interlocks, Ethernet cabling, and Devicenet cabling.

GM Error Proofing System

Industrial PORTFOLIO

GM Error Proofing System

General Motors Corporation, Bowling Green, KY

SPECIFICATIONS

LOCATION

Bowling Green, KY

CLIENT

General Motors Corporation

CONTRACT AMOUNT

$1.7M

FEATURED

Installation of 480V power

Photo Credit: Bowling Green Area Convention & Visitors Bureau

Westphal & Co., Inc. completed the installation of error-proofing and add-on system located at the Corvette Plant in Bowling Green, KY. The project included installation of 480V power, control cabling, cable tray, barcode readers, pull switches, stack lights, pendant lights, selector switches, operator interface (HMI systems), panelviews, and lightboards (Bingo Boards).

GM Skillet Conveyor System

Industrial PORTFOLIO

GM Skillet Conveyor System

General Motors Corporation, Shreveport, LA

SPECIFICATIONS

LOCATION

Shreveport, LA

CLIENT

Acco Systems

CONTRACT AMOUNT

$2MM

FEATURED

Field wiring for 20 conveyor systems and over 175 conveyor elements

Photo Credit: Central Conveyor

Installation of Skillet Conveyor and Automated Electrified Monorail systems for new Light Duty Trim Shop located in Shreveport, LA. The plant was built to meet new demand for light-duty trucks. The project included installation of skillet conveyor and AEM conveyor for final and trim lines including pit wiring, vertical lifts, stackers, de-stackers, and IMC load stations. Westphal & Co. installed field wiring for 20 separate conveyor systems and over 175 separate conveyor elements including control devices, motors, interlocks, and cabling for Ethernet, ControlNet, and Devicenet systems.

GM Cab Box Conveyor System

Industrial PORTFOLIO

GM Cab Box Conveyor System

General Motors Corporation, Shreveport, LA

SPECIFICATIONS

LOCATION

Shreveport, LA

CLIENT

Acco Systems

CONTRACT AMOUNT

$1.5MM

FEATURED

480V power

Installation of material handling conveyor system for new General Motors Paint Shop located in Shreveport, LA was the main objective of this project. This system served as the delivery conveyor from the new paint shop to the new body shop and included 18 separate conveyor systems and 150 separate conveyor elements. The project included skid conveyor, inverted mono-rail conveyor, and pendulum conveyors interlocked with robot cells, paint booths, ovens, and dip tanks. The scope of work included installation of 480V power, control cabling, cable tray, Panelviews/HMI, run/stops, motors, interlocks, and Ethernet, Devicenet, and ControlNet cabling.

Hormel SPAM Line Relocation

Industrial PORTFOLIO

Hormel SPAM Line Relocation

Hormel Foods, Dubuque, IA

SPECIFICATIONS

LOCATION

Dubuque, IA

SIZE

348,000 SF

CLIENT

SSOE Systems, Inc.

CONTRACT AMOUNT

$2.5MM

FEATURED

Controls for complex food processing equipment

Photo Credit: Telegraph Herald

Hormel Foods Corporation relocated its SPAM production facility from Omaha to Dubuque’s 348,000 square-foot Progressive Processing plant. The project included two phases of work – the dismantling of the production line in Omaha and the rebuilding of the line in Dubuque. During Phase I, we traveled to the Omaha plant to thoroughly audit, tag, and test equipment, calculate power requirements, and determine an efficient power and installation plan for the rebuild. The relocation was set to be completed in an aggressive 19 day schedule. The project was midway through when the coronavirus pandemic hit, resulting in a significant spike in demand for SPAM, and making it critical for production to get up and running quickly. Phase I electrical work was completed ahead of schedule and exceeded both the general contractor and client’s quality standards.

Phase II of the project included adding a new production line to the existing facility. Our scope included installation of stainless steel raceways, new lighting, power, and controls for complex food processing equipment. The project required thoughtful and inventive planning in order to integrate various production lines and limit downtime. The efficient and quality work is a product of our partnership with Hormel to oversee ongoing maintenance, service and emergency electrical services at their plant.