ARCO National Construction Completes Empire Bakery Foodservice Facility Expansion While Maintaining Operations

ARCO National Construction completed a 30,100-square-foot expansion and renovation of Empire Bakery’s foodservice distribution and processing facility in Rocky Mount, Virginia. The project significantly enhanced Empire Bakery’s cold storage, processing, and administrative capabilities while allowing the company to remain fully operational throughout construction.

Designed to support increased production volume and improve overall efficiency, the project required detailed planning, phased execution, and close coordination to maintain uninterrupted production and distribution.

The project included a new 13,740-square-foot -5°F freezer and an 8,740-square-foot conditioned warehouse, as well as a full renovation of the existing 7,500-square-foot processing area, enhancing production workflows while meeting strict food safety standards.

Additional temperature-controlled spaces included a new 3,285-square-foot cold dock and the conversion of existing space into a 4,450-square-foot 40°F cooler. To support business operations and staff, a 5,450-square-foot office addition was also integrated into the facility.

Because construction occurred within Empire Bakery’s active facility, maintaining uninterrupted operations was a top priority. ARCO worked closely with Empire Bakery’s team to sequence work in a way that minimized disruption to daily production and distribution activities.

Several aspects of the project required removing and modifying dock positions, which posed a significant risk to ongoing truck access. Through strategic planning and phased execution, ARCO ensured that Empire Bakery never lost access for deliveries or distribution, allowing business operations to continue without interruption.

In addition to expanding cold storage and warehouse space, ARCO renovated multiple areas within Empire Bakery’s production environment. These upgrades included a new cookie production room, a work-in-process cooler, washroom improvements, and enhancements to the mixing area.

Each of these renovations had the potential to disrupt production. ARCO mitigated this risk by implementing value-engineering solutions and carefully coordinated phasing, allowing Empire Bakery to continue production throughout the renovation process.

The facility features a conventional steel frame with insulated metal panels and a commercial Freon split refrigeration system to maintain precise temperature control across freezer, cooler, and conditioned warehouse areas. Additional elements include a 45-mil mechanically fastened TPO roof, 35-foot clear height, and a 7-inch reinforced concrete slab engineered to support heavy equipment and storage loads. Together, these systems support SQF certification and long-term operational performance.

From the outset, ARCO focused on delivering a functional, cost-effective facility tailored to Empire Bakery’s operational needs. By identifying constructability improvements, coordinating refrigeration and structural systems, and sequencing work to align with production requirements, ARCO delivered meaningful value without compromising performance or safety.