Planning Early Makes the Difference
Agropur, founded in 1937, expanded into Wisconsin in 2008 and continues to invest in the state’s dairy industry. The idea for the Little Chute facility emerged in early 2020, driven by increased demand for dairy ingredients and specialty cheeses. While the COVID-19 pandemic slowed progress, planning restarted in December 2020.
As soon as the project was back on track, Mark Minter, Energy Engineer for Agropur’s US Operations, made an important call.
“I contacted our Energy Advisor, Kevin, right away,” said Minter. “I wanted to understand how energy efficiency could be built into the design—and what incentives might be available if we planned ahead.”
That call connected Agropur with one of Focus on Energy's new construction resources, Energy Design Assistance (EDA). The EDA process helps businesses evaluate energy-efficient choices during the design phase, when incorporating energy-saving strategies is oftentimes easier and results in lower operating costs over the lifetime of the building.
Designing with Efficiency Built In
With Focus on Energy involved from the start, Agropur was able to make informed decisions about how the facility would operate for years to come. Energy modeling provided through EDA helped the team compare different design options and understand how each choice affected energy use and cost.
“The EDA helped us look closely at things like HVAC, lighting, and the building envelope,” Minter said. “It gave us clear information so we could choose options that made sense both financially and operationally.”
For complex systems unable to be captured in an energy model, Focus on Energy provides rebate and incentives to support equipment exceeding standard efficiency. Agropur worked with their Energy Advisor, Kevin Kohlbeck, to evaluate other systems for additional energy-saving opportunities, which included:
- Refrigeration
- Compressed air
- Steam and motor controls
- Automation and process systems
Regular design meetings brought together Agropur’s engineers, construction partners, and Focus on Energy experts. This teamwork ensured energy efficiency stayed a priority as plans evolved.
Overcoming Challenges Together
Like many projects started during the pandemic, construction of the Little Chute facility faced challenges. Equipment delays and supply chain issues made timelines harder to manage. Because Focus on Energy was already involved, Agropur was able to adjust project timelines without compromising efficiency goals. “Kevin and the Focus on Energy team worked closely with our contractors,” said Minter. “When delays came up, they helped us find efficient alternatives and kept the project moving forward.” That early and ongoing support helped Agropur stay on track—even when conditions changed.
Big Results That Last
The upgraded facility delivers major results. Agropur more than doubled its processing capacity—from 300 million pounds of milk per year to 750 million, strengthening its operations and Wisconsin’s dairy industry. The project also created more than 50 high-quality jobs and generated an estimated $100 million in economic activity across the state. Energy efficiency played a key role in those results. By designing the facility with efficiency in mind, Agropur earned more than $400,000 in Focus on Energy incentives, received additional support from Kaukauna Facilities, and secured long-term energy savings that will reduce costs year after year. As built, the plant will consume nearly 20% less energy than is required by building code, and the high-efficiency strategies will pay for themselves in under three years.
A Model for Future Projects
The Little Chute facility has changed how Agropur approaches construction in Wisconsin. “This was my first time working with the New Construction team,” Minter said. “But it won’t be the last. We plan to involve Focus on Energy early on every major project moving forward.”
