Frito-Lay ASRS Warehouse & Distribution

Perry, Georgia

A new warehouse becomes part of the long history between Frito-Lay and Haskell.

As one of the largest distributors of savory snack products in the world, Frito-Lay North America, Inc. (Frito-Lay) a Division of PepsiCo, is always on the lookout for new ways to improve its overall productivity and make its supply chain more efficient. To that end, it rolled out the Geographic Enterprise System (GES) program to reduce the amount of manual handling throughout its supply chain. The cutting-edge technology included in the GES program, like Automated Storage and Retrieval Systems (ASRS), enables Frito-Lay to increase SKU capacity with fewer facilities and lower inventory levels.

Haskell collaborated with Frito-Lay to design and construct two new GES facilities.

Haskell was excited to join Frito-Lay on this new endeavor by designing and constructing two new facilities for the GES program in Perry, Georgia. These two warehouses were the largest ever built by Frito-Lay at the time of construction. Both facilities included process, packaging and distribution capabilities for producing some of the company’s potato chip brands. The project scope included an ASRS implementation, truck loading positions and railroad spurs built to accommodate rail cars unloading corn and vegetable oil.

The buildings were constructed simultaneously on an aggressive 11-month schedule. Joint occupancy with the equipment vendor was achieved after eight months, allowing the project to accelerate its final timeline to finish under budget and ahead of schedule. These facilities also included several green environmental features that earned it a LEED Silver Certification.

We have enjoyed mutual success working on multiple projects with Frito-Lay across North America.

Over the years, Haskell has built a strong partnership with Frito-Lay. We have provided architecture, engineering and construction support on dozens of warehouse and manufacturing projects at Frito-Lay locations across North America including Fayetteville, Tennessee; Jonesboro, Arkansas; Lynchburg, Virginia; Orlando, Florida; Topeka, Kansas; Frankfort, Indiana; Rosenberg, Texas; Perry, Georgia; Modesto, California; West Valley City, Utah; Rochester, New York; West Palm Beach, Florida; Waipahu, Oahu, Hawaii; Killingly, Connecticut; and Mexicali, Baja California.

  • GES Pick Center Expansion with two processing, packaging and distribution facilities for the purpose of introducing a new “no fat” oil to product line
  • Each facility is 400,000 SF – the largest ever built by Frito-Lay
  • Automated storage and retrieval system (ASRS)
  • Railroad spurs adequate to maneuver rail cars for corn and vegetable oil unloading
  • Constructed simultaneously in eleven months and joint occupancy for the equipment vendor in eight months
  • Completed under-budget and ahead of schedule
  • LEED® Silver Certification
Vice President – Manufacturing Solutions

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