Winpak’s Manufacturing Facility Expansion, Illinois, United States of America

plastic trays

Winpak's rigid packaging and flexible lidding materials division Winpak Portion Packaging started construction of a 348,000ft² expansion of its existing facility in LogistiCenter at Sauk Village in Illinois, US, in April 2016.

The expansion will renovate the packaging facility, which was opened in 2012 as a part of a major expansion, and also double its manufacturing, office and warehouse space. Chicago Southland Economic Development Corporation (CSEDC) is supporting the project.

Works are scheduled to be completed in the first half of 2017. The project is expected to add 100 jobs to the plant, which currently has 40 employees.

Location of Winpak's packaging facility expansion

Winpak chose Sauk village's LogistiCenter plant for its expansion due to its proximity to the company's South Chicago Heights facility. The business park is surrounded by highway 394 on the east, Cottage Grove Avenue on the west, Sauk Trail on the south and the Canadian National Railway (CN) on the north, making it a strategic location for the investment.

Furthermore, the plant is located within the heavy industrial Calument Expressway corridor, with immediate access to IL 394 highway. It is within six miles of I-80/I-94, making the location ideal to serve the three states of Illinois, Indiana and Michigan.

Other reasons for the site selection include operational history of the company, local employee base and local incentives.

Winpak's Illionois packaging plant expansion details

The expansion will see the addition of 197,000ft² of warehouse space and 137,950ft² of production area. The remaining expansion will comprise an amenity area, maintenance storage, washrooms, mechanical utility room, break room, shipping office, trucker's room and a plant grinding room.

Outside the manufacturing facility, a new second rail spur will be installed along with the development of 12 storage silos, 150 parking spaces, 25 trailer stalls, 20 truck dock loading doors, two new 4,000A electrical services, an exterior drive-in door and a number of one-hour rated openings between the old and new plants.

The expansion also includes renovations to the existing facility, such as development of approximately 15,000ft² of new office area on the second floor. In addition, there will be refurbishing of the main lobby area to provide new stairs and an elevator to the second floor.

Production facilities will be expanded to create more space for lockers rooms and training areas. The maintenance shop offices and tool storage rooms will also get a makeover.

Contractors involved with the expansion

Winpak appointed the same companies that provided construction and architectural services during the construction of the existing facility in 2011.

The project manager is Principle Construction, a leading design/build general contracting company based in Illinois, US, while Harris Architects is the architectural service provider.

"It was constructed with an investment of $30m."

Details of Winpak's existing manufacturing facility at Sauk Village

The existing plastics manufacturing facility is a 32ft clear building situated on a 28-acre site. The plant features production area, warehouse, offices, maintenance area, grinding room, chemical storage room, utilities room and printing area. It was constructed with an investment of $30m, with $1.6m of this was funded by the state of Illinois.

The production area of the plant features a 700t A/C interlocked with specialty exhaust systems, compressed air systems, silo raw material storage and pneumatic delivery systems and is supported by 8,000A electrical service and distribution. The facility's roof has a high load carrying capacity to support the packaging process equipment loads.

A number of LEED components such as T5 lighting, energy monitoring systems and energy-efficient HVAC systems were installed in the facility to make it energy-efficient. Other amenities outside the plant include 15 exterior docks, two exterior drive-in doors, 25 trailer parking stalls, and a rail siding for product delivery.

With thermoforming capacity, the facility produces rigid containers.