Kettle Chips Process Line & Packaging

Client: Confidential
Location: Alberta, Canada


Burns & McDonnell was hired to develop the preliminary engineering and an engineer-procure-construct (EPC) bid package for an expansion of a batch process line and packaging department for a snack chip manufacturer. The project included two new kettle fryers, finished product conveying, and packaging. During the development of the preliminary engineering effort, an alternative scope was developed to provide a $4 million savings and still meet the objective of the expansion.

After the bidding process, Burns & McDonnell was awarded the full EPC project. Our team provided detailed engineering, equipment procurement, and construction for two new kettle fryers, a potato flume transfer system, slicers, a proportional control product distribution system, five new packaging lines and related seasoning equipment, a packaging mezzanine and new infrastructure utilities, including HVAC.

The project required the existing kettle frying system to remain in operation during construction to meet product demand. Burns & McDonnell formulated a construction sequence that enabled plant operations during construction. In order to execute the construction sequence, we temporarily relocated key packaging unit operations and installed insulated metal panel walls to isolate construction areas from the operating plant. By creating a robust isolation, the project team reduced the potential for foreign matter complaints that can result from construction activities.

The project was successfully installed and commissioned on time, within budget and with no impact to product quality.


  • Preliminary engineering
  • EPC bid package development
  • Detailed design
  • Equipment procurement
  • Construction services
  • Shutdown coordination
  • Systems integration


  • $8.5 million total installed cost
  • On time, on budget
  • Less than 1.5 percent total change orders
  • $4 million in value engineering
  • Zero recordables/lost time incidents
  • AIB-recognized for clean construction execution
  • First-of-a-kind packaging structure design