Carolina Foods, a well-established name in the baked goods industry, has officially opened its expansive new production facility in Pineville, marking a significant milestone in the company’s 90-year history. For years, Carolina Foods had recognized the need for a larger production space as their original South End location reached its capacity. This expansion plan gained momentum following the acquisition of Carolina Foods in 2021 by Charlotte-based private equity firm Falfurrias Capital Partners, culminating in the grand opening of this cutting-edge manufacturing operation.
Located at 12031 Carolina Logistics Drive in Pineville’s Carolina Logistics Park, developed by Beacon Partners, the new 428,000-square-foot facility began production in recent months. Carolina Foods signed a long-term lease for this build-to-suit project in 2022, signaling a major commitment to growth. CEO Dan Myers stated that this new facility is poised to double the company’s sales and production capabilities once it reaches full operational capacity. Carolina Foods is renowned for its popular Duchess Brand Honey Buns, alongside a variety of doughnuts and pies, and this expansion will significantly bolster their output of these beloved treats.
The Pineville facility is designed to house seven advanced production lines, complemented by extensive warehousing and modern office spaces for employees. Carolina Foods anticipates employing between 400 and 450 individuals at this location as operations fully transition. While the Pineville facility ramps up, Carolina Foods will continue to operate its original South End bakery, ensuring a phased and seamless transition. Myers refrained from disclosing the exact capital investment in the Pineville project, but emphasized its strategic importance for the future of Carolina Foods.
The initial phase of the Pineville operation is already underway with the launch of the first Honey Buns production line. A second production line, dedicated to doughnuts, is currently being commissioned and is expected to be operational soon. Myers outlined plans to have the first three production lines in Pineville functioning by the end of the current year. These lines will feature entirely new, state-of-the-art equipment, including substantial investments in automation technologies to enhance efficiency and production volume for Carolina Foods.
Looking ahead, the remaining four production lines are scheduled to be implemented in 2025. These lines will incorporate a blend of brand-new machinery and equipment strategically relocated from the existing South End facility, optimizing resource utilization and ensuring a smooth technological transition for Carolina Foods.
“Carolina Foods has thrived for decades by focusing on product quality, reliable service, and the ability to scale production to meet demand,” Myers explained. “This new Pineville facility is a direct investment in amplifying these core strengths, enabling us to better serve our customers and expand our market reach.”
Strategic Location in Pineville: A Key Factor for Carolina Foods
Choosing Pineville as the location for this significant expansion was the result of a comprehensive site search conducted by Carolina Foods, which is celebrating its 90th anniversary. The search encompassed a wide radius of 50 to 60 miles around Charlotte, considering locations in South Carolina, Mecklenburg County, and other counties within the North Carolina region.
Beacon Partners’ Carolina Logistics Park emerged as the ideal solution due to their willingness to undertake a build-to-suit project tailored to Carolina Foods’ specific needs. The expansive site, spanning over 40 acres, also provides ample room for future expansions, a considerable advantage compared to the approximately 6-acre footprint of Carolina Foods’ South End location at 1807 S. Tryon St. The existing South End production facility offers just over 100,000 square feet, with an additional 100,000-square-foot warehouse on South Boulevard. All operations from these South End sites will eventually be consolidated into the new Pineville facility.
Labor considerations were also paramount in the selection of the Pineville site. “The location was truly perfect for our workforce,” Myers emphasized. “Pineville is only 10 miles from our current bakery. We surveyed our existing team members and received overwhelmingly positive feedback regarding commuting to the new location. This was crucial as it allows us to retain the invaluable expertise of our team in producing Honey Buns and doughnuts. Furthermore, the Pineville location offers enhanced access to a broader labor pool, including areas just across the South Carolina border, thanks to convenient highway access.”
The construction of the Carolina Foods project involved a team of leading firms. Whiting-Turner Contracting Co. served as the general contractor, Stellar Group as the interior architect, and Merriman Schmitt Architects led the shell building design. Orsborn Engineering Group provided civil engineering services. Cushman & Wakefield’s Keith Bell and MPV Properties’ Bailey Patrick and Bailey Patrick Jr. represented Carolina Foods in the lease negotiations with Beacon Partners, while Beacon’s Pete Kidwell and Tim Robertson represented the landlord.
South End Site’s Redevelopment Potential
Carolina Foods’ relocation also opens up a prime piece of real estate in Charlotte’s rapidly developing South End for potential redevelopment. The company plans to operate both the Pineville and South End bakeries concurrently until the end of 2025. Myers anticipates full production to be transitioned to Pineville by the end of next year, with Carolina Foods completely vacating the South End location by the end of the first quarter of 2026.
The South Tryon Street site is owned by an entity connected to the Scarborough family, according to property records. The Scarborough family, who previously owned Carolina Foods before the Falfurrias acquisition, remains involved with the company through board representation.
Myers indicated that the landlord intends to repurpose the South End site, recognizing its significant value due to its desirable South End location. While he did not elaborate on specific redevelopment plans, he acknowledged the site’s potential. “The Scarborough family owns that South End site, and they will ultimately determine its future development path,” Myers concluded.
