When Dollar General added candies to its product line, storing these perishable goods at uncooled distribution centers was not possible. Temporarily, candies were placed in onsite refrigerated semi-trailers, which ran 24 hours a day. Baker Group was contracted to retrofit the distribution centers with air conditioning — which also required extensive plumbing, piping, electrical, power distribution and automation systems.

As its single-source provider, for each facility Baker Group:

• Provided an on-site project manager.
• Coordinated with local and state authorities to assure compliance with all regulations.
• Worked with local utility companies to design and install a new 2500 Amp, 480-volt electrical service.
• Installed custom designed cooling system, including of a 1000-ton chiller skid placed outdoors.
• Installed 6” supply and 4” return chilled water lines to 9-12 100-ton air turnover units.
• Completed all control wiring, including a complete CO/NO system.

No interruption to daily operations

Jack Alsted, of Baker Group’s electrical business unit, says, “When employees at Dollar General’s distribution centers get their pick list, they gather those items using a computerized fork lift and have just one route to follow. Before we began work, we met with plant managers to understand their distribution work flow. As a result, we were able to be efficient in our project work and move our equipment up and down their aisles while staying out of their way through the whole project. We never had one glitch.”

Additional cost-saving benefits

In addition to keeping Dollar General’s perishable inventory fresh, the cooling systems have reaped many other benefits. Cardboard packaging on all products stays crisp and doesn’t deteriorate in humid conditions. Employees are more comfortable, which has improved their productivity, satisfaction and retention.

The first project was such a success Baker Group was asked to design and install systems in two more distribution centers.