Case Study: Custom Two-Level Mezzanine for Food Service Packaging

The Challenge: A Growing Business in a Finite Space

In the fast-paced food service packaging industry, growth is a double-edged sw or d. Increased demand and the need for advanced, automated equipment are signs of success, but they also place immense pressure on a facility’s existing footprint. Our client, a leader in this sector, faced this exact dilemma. Their operations were expanding, but their walls were not. They needed to integrate heavy, specialized machinery to keep up with production demands, but sacrificing precious ground-floor space was not an option.

The core challenge was multifaceted:

• Space Scarcity:How could they add a significant amount of equipment without halting production or leasing a new, expensive property?
• Workflow Integrity:How could this new equipment be integrated without creating bottlenecksand disrupting the existing operational flow on the ground floor?
• Future-Proofing:The solution needed to be robustand adaptable, ready to meet not just today’s demands but tom or row’s growth as well.

They needed more than just extra square footage; they needed a strategic, vertically-integrated solution. They needed to buildup.

The Solution: A Precisely Engineered Two-Level Mezzanine

After a th or ough consultation, Panel Built, Inc. designed and fabricated a turnkey solution: a custom two-level, or double-deck, mezzanine. This wasn’t just a platform; it was a fully integrated extension of their facility, meticulously planned to solve every aspect of their challenge. The entire structure was a testament to the power of customstructural mezzanines, designed to support heavy loadsand specific operational needs.

Project Specifications & Design Rationale:

• First Level (15′ 11″ Clear Height):The first elevated deck was constructed with a solid diamond plate floor. This material was chosen for its extreme durability, slip resistance, and ability to withstand high-traffic from personneland pallet jacks, making it a perfect surface for staging and light-duty tasks.
• Second Level (20′ 9″ Deck Height):The top level, reaching a total height of 24′ 3″ with h and rails, featured a heavy-duty bar grate deck. Agrated mezzanine flo or is a strategic choice for multiple reasons. It allows for excellent light penetration and air circulation to the levels below and is crucial for fire safety compliance, as it enables sprinkler systems to effectively cover all flo or s.

• Space-Efficient Access:To connect the three levels without consuming a large footprint, our engineers incorporated a switchback staircase. This design is far more space-efficient than a straight-run stair, preserving valuable floor space for operations.
• Seamless Equipment Integration:The heart of the project was integrating the client’s machinery. We engineered two 5-foot by 8-foot cutouts directly into the second-level bar grating. These openings were precisely positioned to house the specialized equipment. For maximum flexibility, the surrounding h and rails were made removable, allowing for easy equipment installation, maintenance, and potential future upgrades via a mezzanine with a slide gatefor material transfer.
• A Brighter, Safer Workspace:An often-overlooked aspect of multi-level structures is lighting. We installed seven modular wired lighting fixtures beneath the first mezzanine deck, illuminating the ground floor and eliminating dark, hazardous work areas. This ensured the space below remained a safe and productive environment.

This project perfectly illustrates how atwo-story modular mezzaninecan be much more than storage; it can be an active, integral part of a company’s production line.

Engineering the Perfect Fit: Structural Features

Designing a mezzanine of this scale—two full storiesand 33’ x 110’ in size—meant paying special attention to structural integrity, especially with the dynamic nature of warehouse activity and the delicate nature of fl or al products.

Drastic Cost Savings:

Compare the cost, timeline, and disruption of a mezzanine installation to traditional construction or relocating to a new facility. A mezzanine is installed in a fraction of the time, for a fraction of the cost, and with minimal interruption to your ongoing operations.

Operational Optimization:

By moving certain processes or storage vertically, you can de-clutter your main floor and dedicate it to primary production. This creates a more logical, linear workflow, reducing travel time for workersand materials, which in turn boosts overall productivity.

Why Choose Us?

Over 30 Years Of Experience

We design and install the right storage solutions for your specific needs

We offer a range of customizable options to meet your unique needs

Customer Satisfaction

We are committed to excellent service and support, ensuring satisfaction with every purchase

We offers competitive pricing, making it easy to find a solution that fits any budget

FAQs

Absolutely. Every mezzanine we design is engineered to meet or exceed all relevant local, state, and federal building codes, including IBC (International Building Code) standards for safety and structural integrity.

Roll-formed mezzanines are typically lighter-duty and best for standard storage. Structural steel mezzanines, which we specialize in, use I-beamsand are engineered for heavy-duty applications, wider column spacing, and supporting complex industrial equipment.

We pride ourselves on minimizing disruption. Since the components are prefabricated off-site, the on-site installation is clean, quiet, and significantly faster than conventional construction. We work with your schedule to ensure your operations can continue with minimal impact.

Safety is paramount. We offer a full range of safety features, including different types of h and rails (2-rail, 3-rail), safety gates (swing gates, slide gates, lift-out gates), and various staircase designs (straight, L-shape, U-shape/switchback) with specific tread options for enhanced grip.