Fabri-Kal | CSM Group


Project Pure Pulp

Project Details

Client Fabri-Kal

Location Burley, ID

Size (sq. ft) 103,500

Completion Date October 2015


Project Description

CSM Group was selected to serve as the construction manager for the $50 million, 100,000-square-foot manufacturing facility for Fabri-Kal in Burley, Idaho. Fabri-Kal is a leading provider of food service and custom thermoformed packaging solutions.

The project, which broke ground on March 30, 2015, allowed the company to expand their existing product offering and introduce a new, sustainable material into production. The facility extends Fabri-Kal’s footprint in plastics thermoforming and houses initiatives to add to the current Greenware® product line using a new plant-based fiber material.

The building is a pre-engineered metal building fabricated by Ceco Building Systems. The plant portion of the building is approximately 96,000 square feet with an additional 7,500 square feet for offices. The plant is split into four quadrants (warehouse, OMV (plastics thermal molding), pulp preparation, and pulp forming) with each quadrant measuring at approximately 24,000 square feet.

Additional spaces outside of the building included: approximately 4,000 square feet covered and paved for grinding operations; 30,000 square feet for straw storage; approximately 22,000 square feet of paved employee parking; two new entrances onto the property; a fire service loop road; preparation for a rail spur; nine loading docks; approximately 96,000 square feet of trailer storage; and storm water retention.

The new manufacturing facility employed approximately 50 people upon opening, with plans to add 100 people in the next five years. Maintaining Fabri-Kal’s high quality and manufacturing standards, the thermoforming operation will be International Organization for Standardization (ISO) 9001 and Food Safety System Certification (FSSC) 22000 certified.