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    Archived Photos
    Phase 1: 7/09 thru 4/10NEXT UP

    New Plant Progress - First LEED Gold Certified Food Manufacturing Plant in Ohio - Shearer's Foods Inc.

    Shearer's Foods Inc. is proud to present a picture gallery of our latest manufacturing plant in progress.  For higher resolution photos or to schedule a media interview, please see the contact information on the left.

    April 5, 2010 - Processing - heat is recovered from the production process to heat the building, heat sanitation water, and cook water. In this picture, a patented oven uses 24 infrared burners and an enclosed cavity to reduce oven gas usage by 47%.

    April 5, 2010 - The state-of-the-art Massillon facility is now open for production. The building will be constructed with at least 22% recycled materials, and will use 30% less energy in Manufacturing than industry standards.

    February 28, 2010 - The Packaging Mezzanine and associated equipment is approaching completion. The product distribution conveyors and (5) weigh scales have been installed and will feed the tortilla chips to the (5) vertical form, fill and seal packaging machines. Electrical wiring and plumbing to packaging machines and distribution conveyors are in process. The far mezzanine ramp will lead to large scale weigh head bucket washer to ensure product contact surfaces are sanitized to Shearer’s high level requirements.

    February 28, 2010 - The Tortilla Line equipment installation is nearing completion. The fryer and heat exchanger are in place. The downstream seasoning equipment will season the product to provide “Shearer Perfection In Every Bag.® “ The blue belt packaging incline conveyor will deliver the seasoned tortilla chips to the packaging distribution conveyors, weigh heads and onto the form, fill and seal packaging machines. Workers can be seen reviewing schematics and installation specifications to ensure a flawless start up!

    February 28, 2010 - The finishing touches are being completed on this state of the art, targeted for LEED Gold Certification manufacturing facility. To the far left, the (2) white and yellow corn silos and pneumatic conveying system can be seen. As spring approaches and the snow melts, the early April production start up is rapidly approaching!!!

    Packaging Mezzanine
    January 15, 2010 - Packaging Mezzanine will hold scales that will provide infeed of tortilla product to pack off lines below. Wiring, cabling, compressor lines, piping and electrical installation can be seen on the backwall.
    Corn Soak Tanks
    January 1, 2010 - Brand new corn soak tanks are being installed in the corn cook room. These tanks will be monitored and controlled using sophisticated shop floor control systems that will optimize our water usage. Windows in this area will provide supplemental lighting. Both of these measures contribute to reducing the overall energy and utility footprint of this LEED Gold Certified plant.
    Inside view
    December 15, 2009 - Bright blue skies, strong winds and a breathtaking view of our 30+ acres greeted us on the roof of the Massillon Manufacturing Facility. The newly installed skylights can be seen on the roof. These will provide ambient lighting and are a small part of many energy smart enhancements in support of LEED Gold Certification application. The windy conditions delayed installation of the 2 large corn silos for a day. Schumacher and R.G. Smith worked diligently (and carefully) to get these large structures installed.
    December 1, 2009 - A view of the near completed Packaging room. Workers can be seen painting in the foreground. Behind them the Finished Goods docks can be seen with windows above. Temporary lighting and heating has been installed. All floors have been painted with special Urethane paint and hard coating to reduce slippage with maximum durability.

    November 15, 2009 - Construction: North (facing) side of building has a poured Truck and Parking lot. Window installation underway and opening (to left) will allow equipment to be delivered. Workers are preparing the West side of building for sidewalks, parking and a driveway. Inside, the floors are being coated, masonry walls are done, stairs and Mezzanines are being installed.

    November 2, 2009 - Construction: East wall completed with windows installed. In support of our LEED Gold Cerfication, the windows and skylights will improve lighting conditions supplementing conventional lighting during the day.

    November 1, 2009 - Construction: Schumacher Construction site manager discusses ongoing work on the South Docks. The floors are curing but firm enough for crews on lifts to install wiring in the ceiling. 20 by 20 ft ceiling panels are being installed with cut outs for skylights.

    October 21, 2009 - Tour: Terry Mustard, VP of Engineering leads a group of Shearer's Managers, Directors and VP's through the new plant. Each member had the opportunity to ask questions and identify locations for equipment, rooms, etc. In the background, windows have been cut in and will be installed by end of next week.

    October 15, 2009 - Another great aerial shot compliments of Kim Schumacher. Workers can be seen laying roofing on the south end of building. Driveway allows access to the site from the north. Docks that will soon be shipping finished goods are being installed on the north face of the building.

    October 1, 2009 - Internal Construction: Stair Tower is in place. Stairs to be installed that will allow access to the roof. Workers can be seen pouring flooring in the background.

    September 15, 2009 - Construction: Wind braces are being installed. East wall and roof well underway.

    September 1, 2009 - Site Prep: Workers hydro seed the soil to reduce rain run off and dust.

    August 31, 2009 - Construction underway. The frame of the Shearer's Millennium Plant comes to form. Steel workers make great progress between summer storms to get the steel frame constructed.

    August 17, 2009 - Construction Prep: Interior and exterior steel begins to arrive. Selinsky Force carefully manuveurs the steel girders into storage locations. Steel workers will begin laying the vertical and horizontal supports.

    August 3, 2009 - The foundation underway. Exterior and interior footers in place. Parking and stone drive being constructed on North and East side of building.

    July 15, 2009 - Site preparation underway. Brush clearing, rough grading and water mitigation.

    June 30, 2009 - Aerial photo of the newly selected site for Shearer's Foods Inc LEED Gold Certified Manufacturing Plant as taken from Kim Schumacher's bi-plane.
    Site located at 4100 Millennium Blvd, Massillon Ohio 44646