AMERICAN CUSTOM DRYING
Project
As Design-Builder, L.R. Costanzo Co., Inc. partnered with American Custom Drying to expand and modernize its manufacturing operations in Mountain Top, Pennsylvania. The project included construction of a new dryer building addition connected to the existing facility, renovation of an existing tank room into a new process room, and construction of a separate tank storage building. The expansion was designed to accommodate a new commercial spray dryer system used to convert liquid products into powdered form while supporting the owner’s continued growth and production needs.
Challenges
- Constructing foundations adjacent to an existing stormwater detention chamber
- Maintaining construction progress during winter weather conditions
- Coordinating the installation of specialized process equipment within an active manufacturing facility
Solutions
- Collaborated with the project engineers to develop foundation solutions that protected the existing stormwater detention infrastructure
- Utilized ground thaw units, insulated concrete blankets, and winter concrete placement techniques to maintain the project schedule through cold-weather conditions
- Implemented just-in-time material deliveries to minimize laydown requirements and maximize available workspace on the constrained site
Construction Details
- Installation and integration support for a large commercial spray dryer system
- Upgrades to interior finishes and facility components to comply with FDA requirements and industry standards
- Site, utility, structural, and architectural improvements supporting long-term operational growth
