• Food & Beverage

Elopak Carton Packaging

Little Rock, Arkansas

Elopak’s entry into U.S. manufacturing required a facility capable of immediate high-volume output. For their new facility in Little Rock, AR, we installed a robust storage infrastructure supporting the production of liquid dairy and juice cartons. This project required a precise Speedrack Teardrop (K-1000) configuration built strictly to 2021 International Building Code standards. We installed approximately 7,000 pallet positions, standing 27.5-foot (330″) uprights throughout the main aisles and extending End-of-Row uprights to 31.5 feet (378″) to support integrated backstop beams and 24-foot high black nylon safety netting. 

Case Study Quick Facts

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Installing 7,000 Pallet Positions for a New $100M Manufacturing Plant

The Situation

Elopak, a global supplier of carton packaging, made a major move into the U.S. market with a $100 million investment in their first domestic converting plant. Located at 6101 Zeuber Road in Little Rock, Arkansas, this facility produces Pure-Pak cartons for liquid dairy, juice, and plant-based products.

They needed a high-density storage solution to support this new production volume. We partnered with ARCO National Construction to execute the installation. The job required precision to match the new facility’s specs and strict adherence to the 2021 International Building Code. The goal was clear: get 7,000 pallet positions standing and ready for product without delaying the plant’s operational start.

The Work

We installed a Speedrack Teardrop (K-1000) Selective Rack system throughout the warehouse. The layout consists of long runs of back-to-back rows, typically spanning over 165 feet in length.

The Steel Configuration

The uprights here are substantial. We stood standard frames at 27.5 feet (330 inches) high. However, the End of Row (EOR) uprights required different handling—they extend to 31.5 feet (378 inches) to support the upper safety netting and backstop beams. We anchored the first bay of each row to the floor immediately to ensure the entire run remained square and plumb to within 1/4 inch over 10 feet.

Load and Safety Specs

This system is built for weight. The beam levels are rated for a maximum of 3,740 lbs each. To handle that load, we used:

  • Decking: 42″ deep x 46″ wide outside waterfall wire decks, secured with Tek screws in opposite corners to prevent shifting.

  • Bracing: We installed 1.5″ square horizontal bracing and row spacers at three locations vertically to tie the back-to-back rows together for stability.

  • Protection: We bolted down 12-inch tall steel protectors at the ends of rows to stop forklifts from clipping the frame legs.

Visual Management

The client specified a distinct color code for this facility. Unlike the standard “safety orange” everywhere, we installed Light Green (P808) uprights paired with International Orange (P799) beams. This contrast helps forklift operators gauge their fork height more accurately against the green columns.

The Specs

  • Project Type: New Installation / Manufacturing Plant

  • Rack Manufacturer: Speedrack Teardrop (K-1000)

  • Pallet Positions: ~7,000

  • Standard Upright Height: 27′ 6″ (330″)

  • End of Row Upright Height: 31′ 6″ (378″)

  • Load Capacity: 3,740 lbs per level

  • Safety Features:

    • 24-foot (288″) high black nylon netting on single rows

    • 12″ Column Protectors (Yellow P126)

    • 5 Backstop beams per bay on single rows