Bakery Expansion and Relocation to Support Nationwide Growth

Background

Killer Brownie, a producer of premium multi‑layer dessert brownies, experienced rapid growth as demand for its products expanded nationwide. To support this growth, the company pursued a bakery expansion and relocation that would provide increased production capacity while maintaining the quality and consistency of its signature products. 

The existing facility no longer met operational needs, prompting Killer Brownie to evaluate new sites that could accommodate additional make lines, packaging capacity, and improved food safety practices. The expansion and relocation required strategic planning to ensure the selected facility could be adapted to meet hygienic design standards and support long‑term scalability. 

Approach

Our team supported the bakery expansion and relocation through facility planning, process planning, and facility design services. We began by developing a master plan to guide site search and building evaluation, helping identify a facility that aligned with Killer Brownie’s current operational requirements and future growth goals. 

Once the new site was selected, we focused on designing efficient, hygienic production spaces. The scope included the design of mixing and make‑line rooms with sanitary materials and layouts that improved cleanability and product flow. We also designed new ventilation and cooling systems to maintain consistent operating conditions and support employee comfort. 

The facility layout was developed to support three make lines and three packaging lines, providing the capacity and flexibility needed to support increased production volumes. Throughout the bakery expansion and relocation, our team worked closely with Killer Brownie to ensure the new facility supported operational efficiency while positioning the company for continued growth. 

Results

The completed bakery expansion and relocation delivered a modern, 28,000‑square‑foot production facility designed to meet growing nationwide demand. The enhanced layout improved process flow, strengthened hygienic design, and increased overall production and packaging capacity. 

With expanded make‑line capabilities and improved infrastructure, Killer Brownie gained the flexibility needed to scale operations without compromising product quality. The new facility positions the company for sustained growth with a production environment designed for efficiency, food safety, and future expansion.