Hügli – IE Masterplan and General Contracting for an Extension

At its largest production site in Radolfzell, Hügli manufactures and packages high‑quality semi‑finished and finished products. The existing industrial site was expanded to include a fully automated mixing plant with high‑bay and crate storage. Following the joint development of a masterplan, IE Food assumed responsibility for complete general planning and intralogistics planning for this state‑of‑the‑art convenience food production facility.

The Challenge

Until then, production had been distributed across two locations. Consolidation at a single site was primarily driven by economic efficiency. Core elements of the new facility included a fully automated mixing plant and an automated silo high‑bay warehouse with 11,000 pallet positions for raw materials, finished goods and production output. Material flows were integrated into an optimized process design to reliably prevent cross‑contamination between different product categories.

The Success Factors

Hügli deliberately chose IE Food as its planning partner due to its deep expertise in the food industry and cross‑disciplinary experience. Process and plant planning for the new mixing system, followed by transfer to weighing and filling, formed the core of the general planning effort. The industrial buildings were consistently designed from the inside out using coordinated planning and clash detection in a Revit‑based 3D model. This ensured optimal coordination of interfaces across all technical disciplines throughout the planning process. Automated guided vehicles (AGVs) and a sophisticated intralogistics concept further increased efficiency. Operational processes were comprehensively optimized and fully compliant with stringent food production hygiene requirements.