Project Profile
Gatorade Bottling & Distribution
“First and foremost, this project exemplified end-to-end customer service. We have set a new benchmark for speed, cost, quality and customer service that will be hard to beat.”
Arnie Wodke
Director Hot Fill Supply Chain, Gatorade, Division of PepsiCo Chicago
Paul Tyler
Senior Vice President, Food and Beverage

Gatorade Bottling & Distribution

A national brand needed to increase distribution — fast.
When Gatorade needed to quickly increase their bottling and distribution capacity, they called on Haskell to help guide the mammoth effort. After a multi-site search for a new Gatorade manufacturing facility, Haskell was awarded the next-generation bottling facility to be located in Wytheville, Virginia. At completion, it would be the world’s largest LEED® 2.1 Gold food and beverage facility.
We set several key benchmarks in completing the massive project.
The new bottling and distribution facility included 24,000 square feet of offices, 250,000 square feet of process and packaging and a 656,000-square-foot warehouse. Also included in the slab- on-grade project was an on-site rail shed, guardhouse and wastewater treatment plant.
The team powered beyond challenges to deliver on a grand scale.
The project overcame substantial challenges including poor soil conditions, adverse winter conditions, changing business requirements, process and packing requirements, and many others, which were all resolved quickly and professionally. The breakthrough project earned accolades including the ABC Award of Merit, a Tilt-Up Concrete Association Achievement Award and LEED Gold Certification.

Green Features

  • LEED Gold Certified – 44 points. World’s largest LEED Gold Certified food & beverage facility at time of construction.
  • Energy Conservation – HVAC and lighting perform 48 percent better than the baseline ASHRAE standard.
  • Natural Spaces – Preserved more than 50 percent of original site as naturalized open space.
  • Water Conservation – Reduced potable water use by 72 percent.
  • Wastewater Recycling – Methane gas from on-site wastewater treatment system captured and used for boiler fuel.
  •  Renewable Energy Credits – Purchased equivalent to 100 percent of the building’s energy consumption.
  • Green Education Program – sun-tracking photovoltaic array, permanent site and building signage, posters and brochures.
  •  Materials – 15 percent of building materials came from recycled sources, while 40 percent were produced regionally (10 percent produced locally). Diverted 80 percent of construction waste from landfills.
LEED Gold CertifiedLEED® Gold Certified
Wytheville, Virginia, USA
942,034 total square feet.
Fastest hot fill production lines in the world.
Start Date
July 2005

Completion Date
November 2006

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