ESI GROUP USA / (866) 369-3535 / www.esigroupusa.com

SolutionsESI specializes in food processing and distribution center design and construction. SPRING 2013

One Call Does It All

“One phone call does it

all.” That’s how D&G

Transportation Inc. describes

its capabilities and customer

service to prospective new customers in tem-

perature controlled transportation and ware-

housing. A 27-year-old, family-owned com-

pany, D&G offers a full menu of inbound or

outbound shipping, inventory storage and bro-

kerage services for warehousing and virtually

nationwide less-than-truckload shipping.

And when D&G’s success led to the need

for greater capacity, this Germantown, Wis.,

company called another leader in one-stop

services: ESI Group USA.

ESI Group was selected to design and con-

struct a new, 60,000-square-foot, multi-

temp distribution center. Completed in just

seven months (two months early and under

budget!) the new facility includes a ware-

house freezer, cooler and dry storage areas,

as well as dry and perishable docks for prod-

uct receiving, order assembly and shipping. A

one-story general office area and mezzanine

above are included for future offices.

Keeping to one of its other core tenets—

“safety first”—D&G insisted that its new

warehouse meet state-of-the-art require-

ments to keep its people and customer prod-

ucts safe in an energy-efficient structure.

ESI addressed those needs by designing

and installing….

… flooring made with technologically

advanced Ductilcrete, designed to elimi-

nate blemishes that can appear in concrete

floors. This warehouse flooring requires sig-

nificantly fewer floor joints, which often

become problematic.

… docks with state-of-the-art Poweramp

Vertical Storing Levelers complete with inte-

grated control stations. In addition, each

dock position is equipped with a combina-

tion shelter/seal. This allows trailers to back

into the dock door without having to first

open the door. This ensures a greater degree

of food safety by decreasing the risk of tem-

perature loss so product is not exposed to

outdoor elements.

… energy-efficient systems such as an

ammonia refrigeration system complete with

low- and high-temp compressors, condens-

ers, pressure vessels, a vertical re-circula-

tion package and penthouse style evapora-

tive enclosures.

… energy-efficient lighting including flu-

talkto us!

come

UNITED FRESHMay 14-16, 2013San Diego, CABooth 1311

AAMPJuly 18-20, 2013 Charleston, SC Booth 205

� New multi-temperature controlled

distribution center built for D&G in

Germantown, Wisconsin.

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ESI GROUP USA / (866) 369-3535 / www.esigroupusa.com

orescent lighting as well as time-controlled

occupancy sensors. Both the refrigeration and

lighting packages qualify for rebate incentives

through Wisconsin’s Focus on Energy program.

No less important, ESI designed a facility

that is as attractive—as it is functional. That’s

because this highly visible building is on the

corner entrance to Germantown’s Industrial

Park. City commissioners challenged ESI’s

design capabilities by requiring an aesthetically

appealing exterior in order (to avoid the stan-

dard “warehouse” look).

ESI selected decorative insulated metal pan-

els with a stucco texture because they worked

aesthetically for the office area and also func-

tioned well for the warehouse. Panels were

stacked vertically to display multiple colors of

panel along north side of the building, which

faces the main road. The exterior insulated

finish system (EIFS) walls have a stucco texture

similar to the decorative panels. This helps to

break up the structure’s horizontal design. By

utilizing the insulated metal panel, ESI con-

tinued the office facade along the dry ware-

house walls and achieved a design that is both

visually interesting and practical.

Dock design trends and technologies are changing. Here are six points to consider.By Tim Gibbons, ESI Group Vice President of Design

INCREASED USE OF VERTICAL STORING LEVELERS: Vertical

storage levelers are stored inside the dock in an upright position. This facili-

tates pit cleaning, eliminates transfer of cold/heat through the dock plate,

and provides a clean seal at the bottom of the pit for the overhead door. This

also reduces rodent infiltration.

INCREASING DOCK DEPTH: Dock depth of 70’+ feet maximizes

the operational capacity of the dock during receiving and shipping activi-

ties. An entire 53’ load of goods can be staged in front of the doors while

there’s still room for perpendicular traffic at the back of the dock.

INCREASING DOCK HEIGHT: A common misconception during

facility design is that there are operational and construction material sav-

ings if dock height is reduced in relation to the warehouse. On the con-

trary, height advantages can include (1) reduced construction complexity

resulting in lower costs, (2) greater mass of tempered air to reduce large

swings in temperature due to sporadic infiltration, (3) even light distribu-

tion and (4) overhead storage above dock doors.

NEW INSULATED DOORS: Overhead door manufacturers have

redesigned dock doors, increased the level of insulation and effectively

reduced air infiltration. These new doors actually yield an energy payback

on cold docks when used in conjunction with the vertical storage levelers.

IMPROVED DOCK SHELTERS: New dock designs and shelter

accessories allow the trailer doors to swing open—after a truck backs

in (rather than before). This preserves cold chain integrity (in refrigerated

docks) and provides a smooth in-and-out sequence for drivers.

INCREASING RAIL USE: There’s greater interest in rail docks with

more shippers and end customers considering bulk purchase and trans-

portation savings. Rail dock levelers are increasing in use and the related

technology is improving, making these docks easier and safer to use and

also provide the ability to better position cars for unloading/loading.TR

EN

DS

IN…

D&G Warehouse Features• Central ammonia refrigeration system

• Glycol under floor warming

• Insulated metal panel wall construction

• R-Value varies from R-20 to R-50

• Roof construction is TPO

mechanically fastened

• Office walls are stucco textured

insulated metal panels

• Sprinkled with ESFR and dry

pre-action system

• Ductilcrete floors

• Facility is expandable to 150,000 SF

� D&G’s new shipping-receiving dock fea-

tures state-of-the-art flooring and dock

door technologies. It also offers room

for order staging and additional storage.

DOCK DESIGN

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