Bryne Dairy

Ultra-High Temperature Plant Continues Expanding

OUR REPUTATION

After building a plant designed to produce ultra-high temperature processed products, demand for Ultra Dairy’s extended shelf-life products continued to grow. Following up on the initial facility design, AE Design, Inc. was contracted for five more expansions to the DeWitt, NY plant.

In 2003, Byrne Dairy decided the best way to boost sales was to expand its territory. To do so, their products needed a longer shelf life. Because of their reputation in the dairy industry, Ultra Dairy contracted AE Design to design-bid a new ultra-high temperature plant to be located in DeWitt, NY. Since 2006, the plant has undergone extensive expansion and modernization upgrades, boosting its dairy products shelf life from 20 days to 180 days. AE Design’s services have continued to support expansions that added 45,000 sq ft of new processing, packaging, receiving, shipping, and dry storage areas on the site. Infrastructure expansions have included a new refrigeration compressor room, electrical rooms, boiler room, and process utility mezzanines.

In 2013, AE Design was contracted again to design a 120,000 sq ft addition for 7 new filling and packaging lines and the associated utility upgrades needed for increasing capacity. Although Ultra has placed this expansion on hold pending revisions to their product line, AE Design has been trusted with the recent design for a 10,000 SF processing/filling addition and the design of Ultra’s current project consisting of a 35,000 sq ft Cooler/Dock Expansion and 4,000 SF processing expansion.

HIGHLIGHTS

  • Developed a Master Plan for the original UHT plant
  • AE Design provided Design/Bid and Construction Follow up Services
  • Provided Schematic Design and Development Services to clearly define the scope of each expansion.
  • Competed a Refrigeration Stud to allow for the central refrigeration system to support future expansions.
  • Generated all documents for construction and managed the bidding process
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Byrne Dewitt named Dairy Plant of the Year

Byrne Dairy, Inc.’s Dewitt, N.Y., plant was named the 2022 Dairy Plant of the Year by Dairy Foods Magazine for its many accomplishments in aseptic production, food safety, sustainability and much more. A featured article, plus photos and video, are online now at DairyFoods.com.

“It’s a great privilege to be named Dairy Plant of the Year,” said CEO Carl Byrne. “We are grateful for the last 90 years and are looking forward to the future. We owe our continued success to our longtime customers—many who have been with us for decades— and our dedicated employees. Our team continues to go above and beyond to produce a quality product, and we want to extend our gratitude for their commitment and teamwork—this award is for them.”

The fourth-generation family-owned company opened the Dewitt facility—which produces extended shelf life and shelf stable cream and milk products— in 2004 and has expanded about every four years since. The plant now spans approximately 200,000 square feet, not including the newly opened wastewater treatment facility, and employs 210 people.

The Dairy Plant of the Year is awarded annually by Dairy Foods Magazine to a dairy manufacturer achieving outstanding accomplishments in one or more of the following categories: plant expansion/retrofit, new construction, sustainability food safety, employee safety, employee training programs, plant efficiencies, coronavirus-related efforts, new technology and more.

The Byrne legacy dates back to 1933, when Matthew V. Byrne began bottling milk in glass bottles and delivering it (by horse and buggy!) to Central New York families. Today, in addition to the Dewitt plant, the brand operates a Syracuse-based ice cream center and the soon-to-reopen Cortlandville facility, which will also produce extended shelf life and shelf stable dairy.