US Foods – High-Tech Freezer Warehouse & Distribution Hub

Transforming a Warehouse into a State-of-the-Art Facility: The US Foods Project

When US Foods, one of the nation’s largest foodservice distributors, sought to expand its operations in Seabrook, NH, they needed a facility that could handle high-volume distribution while maintaining efficiency, sustainability, and compliance with industry regulations. Jewett Construction was selected to manage this extensive project, which included the transformation of a former Poland Spring facility into a fully operational, state-of-the-art warehouse and distribution center.

Spanning an impressive 500,000 square feet, this renovation required strategic planning and expert execution. Jewett Construction played a critical role in ensuring the project met the highest standards of quality while accommodating the logistical demands of US Foods. This large-scale renovation included interior fit-ups, mechanical and electrical upgrades, and the development of a truck maintenance and fueling facility to support the company’s expansive fleet.

Adapting an Existing Structure for New Demands

Repurposing an existing facility comes with a unique set of challenges. Unlike ground-up construction, working within the parameters of an existing building requires innovative problem-solving and detailed coordination. The US Foods facility had to be adapted to meet modern food storage and distribution standards, which meant significant modifications to layout, infrastructure, and mechanical systems.

Key renovations included:

• A 65,000-square-foot interior fit-up, featuring new offices, training rooms, and operational workspaces.
• High-end kitchen prep areas and product evaluation spaces, ensuring food safety and compliance with industry regulations.
• An interior mezzanine for optimized space utilization, allowing for additional storage and administrative areas.
• A dedicated truck maintenance and fueling facility, designed to keep the US Foods fleet running efficiently.

These enhancements transformed the facility from a standard warehouse into a fully functional hub for food distribution, positioning US Foods for continued success in the region.

Ensuring Compliance with Industry Standards

Food distribution centers are subject to strict industry standards regarding cleanliness, temperature control, and storage conditions. Throughout the renovation process, Jewett Construction worked closely with US Foods to ensure that all work aligned with USDA, FDA, and local health department regulations.

Some of the critical compliance measures implemented included:

• Installation of specialized refrigeration and freezer storage areas to maintain perishable goods.
• Advanced air filtration systems to ensure a clean environment for food handling.
• Non-porous, easy-to-clean flooring and walls to support sanitation protocols.
• Temperature monitoring technology to maintain consistent conditions for stored products.

These measures not only ensured compliance but also helped optimize operational efficiency by streamlining processes and reducing potential product loss due to environmental fluctuations.

Designing for Efficiency and Functionality

The layout of a food distribution center is critical to maintaining smooth operations. Efficiency in movement, storage, and logistics directly impacts productivity. Jewett Construction worked with US Foods to design a space that minimized unnecessary travel time for workers and maximized available storage.

Enhancements to the facility’s efficiency included:

• Dedicated areas for receiving, processing, and dispatching goods, reducing congestion and bottlenecks.
• Ergonomically designed workspaces to improve employee comfort and safety.
• Optimized racking and shelving solutions to maximize vertical storage capacity.
• Strategic placement of loading docks for seamless product flow in and out of the warehouse.

With these features, the facility was designed to keep pace with the high-volume needs of US Foods while maintaining safety and ease of use for employees.

Sustainability and Energy Efficiency Upgrades

As part of the renovation, Jewett Construction incorporated sustainable building practices to improve energy efficiency and reduce the facility’s environmental footprint. Given the size of the warehouse and its constant energy demands, these upgrades played a vital role in long-term cost savings and sustainability efforts.

Green building initiatives included:

• LED lighting systems with motion sensors to reduce unnecessary energy consumption.
• High-efficiency refrigeration units to lower operational costs.
• Improved insulation and air-sealing techniques to maintain consistent indoor temperatures.
• Advanced water conservation measures, including low-flow plumbing fixtures.

By integrating these energy-saving features, the facility aligns with US Foods’ commitment to sustainability while also reducing long-term utility expenses.

Maintaining Operations During Construction

A major challenge of this renovation was ensuring that construction activities did not disrupt the ongoing operations of US Foods. Coordinating work schedules, minimizing downtime, and maintaining a safe environment for employees were top priorities.

Jewett Construction took the following steps to ensure seamless operations during the renovation:

• Implementing phased construction to allow for continued use of key areas.
• Establishing designated work zones to minimize interference with daily activities.
• Utilizing off-hours work shifts to complete critical tasks without impacting operations.
• Maintaining clear communication with US Foods leadership to address concerns in real time.

Through careful planning and execution, Jewett Construction successfully completed the project without causing major disruptions to US Foods' workflow.

Impact on US Foods and the Local Economy

The completion of this facility has had a significant impact on both US Foods and the surrounding community. As a major employer in the area, the expanded warehouse and distribution center has created new job opportunities while also improving service capabilities for restaurants, schools, and businesses that rely on US Foods for supplies.

Key benefits include:

• Increased distribution capacity to support growing customer demand.
• Enhanced working conditions for employees with modernized facilities.
• Strengthened supply chain resilience through efficient logistics solutions.
• Economic growth through job creation and infrastructure improvements.

As a result, this project not only benefits US Foods but also strengthens the overall foodservice industry in the region.

A Model for Future Distribution Center Projects

The success of the US Foods project serves as a blueprint for future distribution facility renovations. Jewett Construction’s approach—balancing operational needs, sustainability, and efficiency—demonstrates how existing warehouses can be transformed into modern, high-performance spaces.

Looking ahead, the strategies used in this renovation can be applied to similar large-scale projects across industries, particularly those requiring specialized storage and logistics capabilities.

Building for the Future

With the completion of the US Foods project, Jewett Construction has once again demonstrated its ability to deliver high-quality, large-scale industrial renovations. By combining expertise in construction management, compliance, sustainability, and logistics, Jewett has created a facility that will serve US Foods for years to come.

As businesses continue to expand and modernize, Jewett Construction remains committed to delivering innovative building solutions that support growth, efficiency, and long-term success.