Green Bay Packaging

Green Bay Packaging’s 650,000 SF Super Plant Opens in Fort Worth, TX

Fort Worth, TX

They call it a “Super Plant,” and for good reason.

At 650,000 SF, this massive manufacturing facility for Green Bay Packaging in Fort Worth, Texas, is a feat of engineering and design. The $61 million facility sits on 46 acres and includes 560,000 SF of manufacturing floor space and 52,000 SF of multistory office and mixed-use areas.

The project features 32 docks, a rail dock with railroad extension, state-of-the-art machinery, and advanced conveyance systems.

Unique Finishes
Exterior finishes included primarily tilt wall, ACM, metal panels, and architectural sunshades/louver screens. The office gallery features museum-style skylights, adding an elegant touch.

Interior finishes were a blend of painted tilt walls, custom wood walls, graphics, and glass railings at the atrium lobby. The facility also includes a rail spur and rail dock for material deliveries.

Specialized features include advanced HVAC systems, industrial compressed air systems, and automated cooling and extraction systems to support the manufacturing space.

Texas-Sized Challenges
The challenges on this project were almost as large as the facility itself:

MEP Design: The lack of key equipment requirements and end facility needs from the owner created significant design hurdles. Most of these changes came during the last four months of the project, causing schedule and cost impacts. Crossland stepped in to align with the owner’s needs, ensuring their equipment was operational to begin production on time.

Weather Delays: Unfavorable weather caused construction delays, but Crossland worked closely with subcontractors to re-sequence the job and get spaces dried to accept delivery of the owner’s manufacturing equipment. The equipment, sourced from countries like Italy, Germany, Japan, and Korea, required precise scheduling and coordination.

Utility Delivery: Facilitating design changes for electrical, plumbing, and mechanical systems to support the owner’s complex equipment added another layer of complexity. Crossland collaborated with numerous owner-hired contractors and equipment installers to meet manufacturing timelines.

A Rewarding Outcome
Despite the challenges, the Crossland team successfully completed the facility, meeting the owner’s needs and addressing obstacles through careful coordination and problem-solving. This project demonstrates the team’s ability to manage complex builds and deliver a high-quality facility designed to support advanced manufacturing operations.

Project Facts

Industry Sector: Industrial
Cost: 8,989,000
Size: 600,000 SF
Delivery Method: Design-Bid-Build / Hard Bid, Negotiated
Owner: Green Bay Packaging Inc.