Fusion Projects completed the transformation of a 30,000-square-foot industrial warehouse in Delta, BC, creating a CFIA-compliant food packaging and semi-automated warehousing facility for Dan-D Pak.

The project was designed to transfer and expand Dan-D Pak’s nut and oat packaging operations from its existing facility into a newly acquired property, requiring the conversion of conventional warehouse space into a highly specialized food production environment.

Working in partnership with design team Thermo Design Insulation Canada (TDI) and the project’s consultant team, Fusion helped establish a minimum viable design that balanced regulatory requirements, operational needs, budget, and an accelerated construction schedule.

Early coordination played a significant role in moving the project forward. Fusion aligned the consultant team around CFIA requirements while incorporating insights from Dan-D Pak’s operations in Vietnam to ensure the new facility met both Canadian regulatory standards and the company’s broader operational requirements. A simplified permit package was submitted early and subsequently developed through phased revisions, helping streamline approvals and allowing mobilization and construction to begin sooner.

Value engineering continued throughout design and construction. Fusion worked with consultants to optimize the HVAC and electrical scope while maintaining the infrastructure required for Dan-D Pak’s production and packaging operations. During construction, the team also collaborated with consultants and trades to redesign the sprinkler integration within the automated racking system, eliminating the need for in-rack sprinklers and reducing both cost and installation time.

Material and equipment procurement required a similarly strategic approach. Fusion evaluated insulated metal panel (IMP) wall systems sourced from Asia, Europe, and North America to identify a solution that balanced cost, lead times, code compliance, and performance. Close coordination with the selected IMP wall vendor helped expedite production and installation to keep the facility aligned with Dan-D Pak’s operational timeline.

Construction sequencing was planned around business continuity and early occupancy. By staging the delivery and installation of the automated racking system, Dan-D Pak was able to begin occupying the facility and installing its production and packaging lines before the racking scope was complete. This approach accelerated commissioning and helped transition operations into the new facility sooner.

Completed in 2026, the project brings together food-grade construction, semi-automated warehousing, specialized production infrastructure, and strategic value engineering within a facility designed to support Dan-D Pak’s expanded operational capacity.