Industrial Processing Facility Expansion | Food Production Infrastructure
The Smith’s Poultry Processing Plant Expansion was a major industrial construction project designed to increase production capacity, modernize processing systems, and improve operational efficiency for one of the region’s leading poultry suppliers.
With demand for poultry products continuing to grow across the Southeast, Smith’s Poultry partnered with our construction team to deliver a comprehensive facility expansion that would support increased processing volume while maintaining strict food safety and operational standards.
The project involved the construction of a new processing wing, cold storage facilities, upgraded utilities infrastructure, and expanded loading dock operations, all while the existing plant remained fully operational.
Through careful planning, phased construction, and close coordination with plant management, the expansion was completed safely and efficiently with minimal disruption to daily production.
Client: Smith’s Poultry
Industry: Food Processing / Agriculture
Project Type: Industrial Facility Expansion
Project Size: 85,000+ Square Feet Added
Construction Value: $24.6 Million
Timeline: 16 Months
Location: Southeastern United States
The centerpiece of the project was the construction of a new processing wing designed to house advanced poultry processing equipment and automated production lines.
Key features included:
Reinforced structural steel framing
Sanitary wall systems designed for wash-down environments
Food-grade epoxy flooring
Temperature-controlled processing areas
Integrated overhead conveyor systems
USDA-compliant facility design
This new space allowed the facility to increase production capacity by nearly 40%.
A significant portion of the expansion focused on increasing cold storage capacity to support growing distribution demands.
Work included:
Construction of two large refrigerated storage warehouses
Installation of industrial ammonia refrigeration systems
Insulated panel wall construction
High-efficiency loading dock doors
Temperature monitoring and automated controls
The upgraded cold storage allows Smith’s Poultry to safely store and distribute significantly higher product volumes while maintaining strict quality standards.
To support the expanded operations, the project required substantial upgrades to the facility’s utility systems.
Our team installed:
New electrical distribution systems
High-capacity water and sanitation systems
Steam and process piping
Industrial ventilation and air handling systems
Backup power infrastructure
These upgrades ensure the facility can support long-term growth and increased processing capacity.
To improve shipping efficiency and product flow, the project included the construction of an expanded logistics and loading dock area.
Improvements included:
Eight additional truck bays
Reinforced concrete dock structures
Dock levelers and hydraulic lift systems
Traffic flow redesign for shipping operations
Expanded staging and pallet storage areas
These upgrades significantly improved distribution efficiency and reduced truck turnaround time.
One of the most complex aspects of the project was performing large-scale construction while the plant remained in full production.
Our team implemented:
Phased construction scheduling
Strict safety and sanitation protocols
Controlled access zones
Off-hours utility tie-ins
This approach ensured plant operations continued uninterrupted while expansion work progressed.
Because the facility operates under strict USDA and food safety regulations, construction materials and methods had to meet rigorous sanitation standards.
Specialized materials such as wash-down rated walls, corrosion-resistant fixtures, and antimicrobial surfaces were incorporated throughout the processing areas.
The Smith’s Poultry Plant Expansion successfully delivered a modernized processing facility capable of meeting growing market demand while maintaining the highest standards for food safety and operational efficiency.
The completed expansion resulted in:
40% increase in processing capacity
Expanded cold storage for regional distribution
Improved logistics and shipping efficiency
Upgraded infrastructure for long-term operational growth
Today, the facility stands as a state-of-the-art poultry processing operation supporting hundreds of jobs and supplying poultry products to retailers and distributors throughout the region.
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