Your Trusted Partner in Modern RTE Food Processing

Expert Solutions for Safe and Efficient RTE Food Facilities: Stellar's Proven Track Record

As a seasoned expert in designing and constructing facilities for the world's leading food manufacturers, including Boar's Head, Columbus Foods, Kraft Heinz, Nestlé, and Cuisine Solutions, Stellar possesses an intimate understanding of the diverse requirements of modern-day RTE (Ready-to-Eat) food processors. Within the prepared and ready-to-eat foods industry, we embrace an integrated approach, delivering comprehensive services from project inception to completion. This encompasses assisting in site selection and permitting, crafting world-class facility designs and construction, process engineering, procuring and installing process equipment, and overseeing facility and process commissioning and startup.

The prevention of allergen and microbial-related recalls demands adherence to stringent sanitary design best practices for both building and process equipment design—a facet in which Stellar excels. Our expertise has been instrumental in defining the industry's widely accepted 11 food safety principles.

Our adept team of experts establishes distinct zones of control to segregate production areas for raw materials from those dedicated to cooked, ready-to-eat products. Moreover, we ensure that employee welfare and support areas remain separate to prevent any contact between individuals exposed to raw ingredients and those working in critical hygiene work centers handling RTE products.

As technology's role continues to expand in the industry, understanding best practices for robotics and process control systems becomes paramount. In this aspect, Stellar is well-versed, exemplified by our achievement in developing the industry's first-ever triple-lane assembly line for Heinz’s frozen-food processing plant. This remarkable line, believed to be the fastest entree line in North America, produces an astounding 9 million cases per year, underscoring our mastery of speed and efficiency.

With Stellar as your strategic partner, you gain access to a wealth of knowledge and a proven track record in crafting cutting-edge solutions for the RTE food processing industry. Our commitment to excellence and innovation is the driving force behind our unwavering pursuit of success for our clients.

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Stellar has been a solid fit for Heinz. They have well-grounded people who work hard and understand our business. Their knowledge of the food and beverage industry continues to grow, specifically within their process and packaging engineering group. While they offer the typical A/E/C skillsets, they also understand and are gaining valuable real-world experiences of what happens inside the box, which adds considerable value for an owner.

I’ve worked with Stellar since the 1990s, and they have been very consistent in their project approach. They are careful in their planning, management and organization of the project. And while the process is structured, they are also flexible and responsive to project change.

I’ve also found Stellar’s people to be highly focused on value. They produce the right amount of deliverables, without adding drawings or specifications that aren’t needed. They are cognizant of budgets and pride themselves on delivering against budget.

Mike Keough
Senior Project Manager

Nestlé has had an ongoing business relationship with Stellar for approximately 10 years, and they have successfully completed several major industrial design-build construction projects in various locations ranging from $1 million to $140 million in value. The projects were executed in a professional manner and were delivered within the established schedule and budget. Stellar’s professionals have the experience, knowledge and skill sets necessary to properly design and execute large projects effectively.

Renato Becker
Sr. Project Manager

I am proud of the thoughtfulness, commitment and quality of work Stellar has demonstrated through the design, construction and commissioning of our production facility. Teamwork is critical to any project; the Starbucks and Stellar teams worked well together to achieve a first-class production facility.

Brent Denniston
VP of Manufacturing, Engineering and Quality