The expansion added 200,000ft² of manufacturing and warehouse space. Credit: Accredo Packaging.
The ground-breaking of Accredo's plant expansion was held in 2018. Credit: Accredo Packaging.
The extrusion line at the facility supports the production of lightweight breathable films. Credit: Accredo Packaging.

Accredo Packaging, a provider of conventional, compostable, renewable and flexible packaging solutions, has expanded its facility in Sugar Land, Texas, US.

The company broke ground on the expansion of the North American production facility in July 2018 to increase the capacity of the existing facility, which was opened in 2009. The latest expansion increased the size of the facility to nearly three times the original area.

The total estimated investment across the three phases of project development since 2009 is $200m, while the recent expansion involved an investment of $50m. The Fort Bend County Industrial Development Corporation (FBCIDC) provided financial assistance for the expansion of Accredo Packaging’s facilities in the county. The expansion of the Sugar Land manufacturing plant was completed in the first quarter of 2020.

Accredo Packaging’s plant location and details

The packaging plant is a 32-acre campus located at 12682 Cardinal Meadows Drive in Sugar Land, Fort Bend County, Texas.

The expansion increased the manufacturing and warehouse space of the plant by an additional 200,000ft². With the completion of the project, the facility spans an area of 550,000ft².

The facility includes a 4,000Amp underground power supply, and two 500t air-cooled chillers for production equipment.

Accredo Packaging’s plant expansions

Phase one of the packaging plant expansion involved the development of a 170,000ft² LEED Silver-accredited facility. During the first phase, 6,664ft² of office space, a 3,000ft² ink room, a 44,500ft² dock high warehouse, and 104,268ft² of manufacturing and distribution space were built.

“The total estimated investment across the three phases of project development since 2009 is $200m.”

It also included the installation of blowout panels in the exterior and blowout relief panels in the ceiling, and a special foam sprinkler system.

The second phase in 2013 added 175,000ft² of new area, including a 155,263ft² warehouse facility and an office building spread across an area of 17,837ft².

The 200,000ft² expansion in phase three created 165,000ft² of new warehouse and office space, as well as a 35,840ft² manufacturing space. The third phase also added two new rail spurs and 1,825ft of railroad track with a crossover and accommodations for drainage.

Project benefits

The project will increase the production capacity of high-definition flexographic printing, bag and pouch making, and adhesive lamination. It also expanded the company’s annual flexible film production from 1.5 billion feet to two billion feet.

The expansion is projected to create 175 new jobs in the Sugar Land area, increasing the workforce from 350 to 525.

Sustainability features

The packaging plant was the first flexible packaging plant in the US to receive Leadership in Energy and Environmental Design (LEED) Silver certification under the US Green Building Council (USGBC) rating system.

Accredo Packaging is also accredited with ‘AA’ certification of British Retail Consortium (BRC).

The company uses 100% wind-generated electricity to meet its operational needs at its North American location. The facility is also equipped with systems and processes to eliminate waste and reduce carbon emissions.

Details of the existing packaging plant

The facility features multiple W&H extrusion lines with nine-layer capability. A new W&H blown film extruder incorporated with inline stretching (MDO) capability was also installed.

The plant has also been installed with three new ten-colour W&H flexographic presses and a new three-layer tandem laminator with registered coating capability.

Contractors involved in Accredo Packaging’s plant expansion

Kingham Dalton Wilson (KDW) was awarded a contract for the expansion of the plant. The company was responsible for the design and construction of the new building to the south of the existing facility. It was supported by TGB Group and Railworks on the project. TGB and Railworks performed the survey, design and construction of railroad track for the packaging plant.

Accredo Packaging’s product portfolio

The brand offers products such as coextruded films, printed, laminated barrier film rollstock, wicketed bags, pouches, and bundling and overwrap film. The company incorporates advanced technology in the manufacturing of flexographic printing, blown films, adhesive lamination and pouch and bag making.

The firm offers its products for different segments, including compressed packaging, beverages, snack foods, pet treats, and lidding.

Marketing commentary on Accredo Packaging

Accredo Packaging provides innovative and sustainable flexible packaging solutions for customers in the consumer products and pre-packaged foods markets.

Accredo Packaging is a part of the API Group of Companies, which was established in 1986. It became the first company to produce a reverse-printed and laminated all-recyclable stand-up pouch.

The company received the FTA Sustainability Excellence Award in 2014. It is focused on meeting the increasing demand for flexible packaging to ensure greater shelf life of products.