DePue Mechanical helped build the first fully automated caramel popcorn plant in the U.S., providing stainless steel piping, equipment setting, and utility tie-ins for a turnkey food manufacturing upgrade.
Mechanical Equipment & Piping Installation
Industrial Piping, Heavy Equipment Setting & Steel Fabrication, Boiler Installation & ASME Code Welding Services in Chicago
2017-2018
Waukegan, Illinois
The client’s existing caramel popcorn operation relied heavily on manual handling and outdated equipment, leading to inconsistent product quality and limited output. Their goal was to automate the entire process—from caramel mixing to final packaging—without expanding the facility footprint or interrupting other production lines.
Key project challenges included:
- Integrating new automation with legacy systems
- Tight installation windows in an active food production environment
- Compliance with USDA and food safety standards
- Coordination with multiple vendors and OEM equipment manufacturers
DePue Mechanical served as the mechanical contractor from design through startup, providing full design-build support, utility layout, and field installation.
We were proud to help our client build the first fully automated caramel popcorn plant in the United States—a groundbreaking project in food manufacturing. Our team completed all work in an existing facility, requiring precise planning, custom fabrication, and skilled trade execution.
Scope of Work Included:
- Fabricated and installed a 38' x 90' stainless steel platform for the automated popcorn process
- Installed new footings within the active facility to support heavy processing equipment
- Set kettles, mixers, conveyors, and pumps, ensuring accurate alignment and startup readiness
- Performed stainless steel orbital welding for all process piping connections
Installed full utility piping systems including:
- Hot oil supply and return lines
- Natural gas piping
- Pre-mix piping, slurry piping, syrup piping, and butter piping for caramel coating
We coordinated with OEM vendors, controls integrators, and the plant’s maintenance staff to ensure every system was installed to spec and met USDA food safety standards.
Our work helped the client launch a first-of-its-kind automated system with measurable operational improvements. Key project outcomes included:
- First fully automated caramel popcorn plant in the U.S.—a milestone project for the food & beverage industry
- Enabled the client to scale output rapidly while reducing manual labor and batch inconsistencies
- Seamless integration of custom-fabricated platform, hot oil systems, and food-grade process piping
-Delivered all work within an active facility, without disrupting existing production
- Achieved full compliance with food safety and utility code standards, including orbital-welded stainless systems
- Completed the entire scope ahead of schedule and under budget, with zero safety incidents
DePue Mechanical partnered with a national snack food manufacturer to design and install a fully automated caramel popcorn production line at their Illinois facility.
With growing demand and outdated manual systems, the client needed a mechanical contractor who could handle complex food-grade piping, automation coordination, and aggressive deadlines—all without disrupting ongoing operations. This case study outlines how we delivered a complete turnkey solution, including stainless steel piping, utility tie-ins, equipment setting, and automation integration, to bring a high-output, food-safe caramel popcorn system online—on time and under budget.
If you're planning an automation upgrade or system expansion in your food manufacturing facility, partner with a contractor that understands the complexity of food-grade mechanical installs.
Contact us to get started.
