Bakerly Ranch

Bakerly

Factory in San Antonio is to produce authentic French bakery products while expanding its U.S. operations and creating local jobs.

As the architects for the project, we had designed the facility to ensure it meets the complex manufacturing process requirements that Bakerly has developed as well as planning for the future as the entire facility will need to be expandable with future phases as well as meeting LEED certifications for sustainability.

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The Project

This endeavor is crucial for the client, as it will significantly expand their operational capabilities nationwide. Located at Brooks City Base, a growing economic development hub in San Antonio, this facility will be pivotal for scaling production. The decision to build here was influenced by the area's strong community, the potential fornew partnerships, operational growth, and access to a talented workforce.

The Methodology

The primary challenge of the project was the intricate structural coordination and integrating the owner’s production line. The design had to account for future expansion, incorporating removable columns and extendable structural trusses. The complexity of the owner's production line also posed a significant challenge, as the facility's equipment spans over 540 feet, featuring a conveyor system that moves product through various stages to transform dough into a packaged product ready for shipping. Meticulous planning and collaboration were essential to ensure that the structure could accommodate both current operations and future growth.

The Result

Currently in its initial phase, the facility already employs over 50 people, and once fully expanded, it will support over 200 employees. With the capability to meet both customer and retail partners' demands, the facility plays a key role in the company's nationwide shipping operations, particularly supporting their Easton location. As the facility continues to grow, it will not only boost the company’s production capacity but also contribute to the local economy and provide significant employment opportunities within the Brooks City Base area.

Client

Bakerly

Location

San Antonio, Texas

Year

2024

Services

Size

·        135,000SQFT Facility

·        5,500SQFT Freezer

·        2,000SQFT Breakroom

·        4,000SQFT Administrative Offices

·        7,000+SQFT Production Offices

·        50,000SQFT Covered Solar Panel Carport

Key Features

·        Entire facility, including freezer, locker rooms, administrative offices, and production space, is expandable for future growth

·        Solar panel carport can generate enough power to charge 133 million smart phones annually

The Project

This endeavor is crucial for the client, as it will significantly expand their operational capabilities nationwide. Located at Brooks City Base, a growing economic development hub in San Antonio, this facility will be pivotal for scaling production. The decision to build here was influenced by the area's strong community, the potential fornew partnerships, operational growth, and access to a talented workforce.

The Methodology

The primary challenge of the project was the intricate structural coordination and integrating the owner’s production line. The design had to account for future expansion, incorporating removable columns and extendable structural trusses. The complexity of the owner's production line also posed a significant challenge, as the facility's equipment spans over 540 feet, featuring a conveyor system that moves product through various stages to transform dough into a packaged product ready for shipping. Meticulous planning and collaboration were essential to ensure that the structure could accommodate both current operations and future growth.

Additional Experience