Lollicup USA, a disposable foodservice packaging products producer, is developing a new manufacturing facility in Rockwall, Texas, US.

Being built with an investment of $50m, the new facility will manufacture paper and plastic cups, as well as other food containers. It will enable the company to meet the needs of regional customers and increase production capacity.

The land development deal for the project was signed in July 2017. Construction of the manufacturing facility is expected to be completed by early-2019.

Lollicup USA is expected to employ 200 new employees at the facility.

Location details of Lollicup USA manufacturing facility

Lollicup USA’s new manufacturing facility is being developed on a 34.23-acre site in the phase two development of the Rockwall Technology Park.

The 400-acre park offers ready-to-build sites, utilities and common area landscaping. It also offers easy access to five interstates, infrastructure, and skilled workforce.

Lollicup USA manufacturing facility construction and design details

The new manufacturing facility will cover an area of 660,000ft², which includes 27,000ft² of office space. The building will feature tilt-up concrete wall panels and a 32ft-high steel structure. The concrete wall panels will be made of natural stone and anodised aluminium and feature a tinted glass curtainwall.

“Lollicup USA’s new manufacturing facility is being developed on a 34.23-acre site in the phase two development of the Rockwall Technology Park.”

Construction of the building required 209 24in piers, 650,000ft² of 7in slab-on-grade and 150,549ft² of tilt wall panels, as well as 68 dock leveller pits.

The roof of the building features a steel deck made of R-20 rigid insulation covered by a thermoplastic polyolefin membrane. The facility also features 66 overhead loading dock doors and three drive-in doors.

The office area of the facility includes a café featuring indoor and outdoor dining patio facilities for employees.

The new facility will be installed with Koenig & Bauer’s Flexotecnica Evo XG press, which is equipped with a number of automated features. The press offers improved printing widths and higher printing speeds that help to increase efficiency and productivity.

It is also equipped with a high-precision solid print deck, which features anti-vibration components that provide flexibility when printing at high speeds.

Lollicup USA products

Lollicup USA manufactures its disposable products under two brands namely Karat® and Karat Earth®.

The Karat® brand includes a wide range of high-quality disposable food and beverage products such as cups, containers and utensils, while the Karat Earth® brand offers similar products made of renewable materials.

Some of the products provided by the company include cups and lids made from polypropylene (PP), polyethylene terephthalate (PET) and paper, as well as stirrers and straws in varying lengths and sizes.

Others products include cup accessories, portion cups and lids, deli containers, injection moulded bowls and deli containers, plastic hinged containers, food buckets, paper food trays, fold-to-go containers, food pails, aluminium containers, take-out bags, deli wrap sheets, spoons, forks, and napkins.

Contractors involved

The manufacturing facility was designed by BatesForum, while landscape architect is Forum Studio Architects.

The general contractor for the project is Clayco, which subcontracted Kent Companies for concrete work.

Freese & Nichols is the civil engineer for the project. The company was responsible for the complete civil engineering design of the project, including coordination with the city council, drainage system design, fire protection, and paving and grading design.

Koenig & Bauer was contracted in August 2018 to supply its Flexotecnica Evo XG press for the new facility.

Marketing commentary on Lollicup USA

Established in 2000, Lollicup USA manufactures and supplies disposable food packaging products made of paper and plastic to retail businesses and franchises. It also supplies drink and dessert ingredients under its Tea Zone® brand and cleaning products under its Total Clean brand.

The company currently operates from four locations in the US, including Texas, Washington, South Carolina, and New Jersey.

The Rockwall facility is the second facility announced by Lollicup USA in 2018. The company opened a new warehouse in New Jersey during the year, which will help in serving its east coast customers quickly and effectively.