LIBERTY, S.C. – A M King, an integrated Design-Build firm, has completed a large-scale renovation project for U.S. Waffle Company, Inc. in Liberty, S.C. The 310,000-square-foot bakery houses five production lines with capacity for nine lines, positioning the international food manufacturer for continued high growth in the breakfast products category.
U.S. Waffle manufactures and distributes specialty frozen waffles and pancakes through its retail division (supermarkets) and food service/institutional division (restaurants, schools and prisons) nationwide and internationally.
U.S. Waffle, which outgrew its original facilities in Greenville, S.C., purchased a local manufacturing landmark directly south of downtown Liberty, at the intersection of US 123 and State 178, 15 miles from I-85. The warehouse was built in 1981 and features a 1970s design with reflective glass on the exterior, expansive windows, sizable extensions in front of the main entrance and a large outdoor employee break area. The project is an interesting study in not only how to adapt and reuse an existing building for a new purpose, but also the best way to source repurposed construction materials.
A M King’s scope of work included production line layout and design consulting; processing and packaging space build-out; HVAC selection to maintain positive pressure through different stages of the baking process, and electrical coordination. Renovations included the warehouse, food processing areas, dry storage, dry docks, offices and Quality Assurance labs.
In addition, A M King installed 1,550 cubic yards of concrete with sloped surfaces to minimize labor during washdown. Repurposed materials procured by the owner — that otherwise would have ended up in a landfill — include industrial sinks, wall panels, relief dampers, an emergency generator, electrical switch gear, storage racking, furniture and exhaust fans.
“The owner’s level of involvement and enthusiasm for using recycled materials presented a unique and collaborative project environment,” says JD Boone, A M King project manager.
“Our team derived great satisfaction from assisting the owner in both saving money and resources while meeting complex building code and food sanitation standards,” says Matthew Jones, A M King lead designer.