PREMIER Delivers New Headquarters for Carlson

October 22, 2024 (Lincolnshire, IL) -- PREMIER Design + Build Group celebrates the grand opening of a 188,000-square-foot laboratory renovation project for industry leader Carlson Nutritional Supplements, a family-owned and female-led manufacturer of vitamins, minerals, omega-3s, kids' products and other nutritional supplements. The PREMIER team turned a nearly 50-year-old warehouse and two-story building in Lincolnshire, Ill., into a state-of-the-art laboratory and production facility. 

The renovation included the warehouse where vitamin production, packaging, storage, and shipping occur, as well as an attached building with a research and development laboratory and office space. Many upgrades were required to turn the warehouse and office building, originally constructed in 1980, into a modern facility. 

Carlson and PREMIER’s strong partnership prioritized collaboration and trust throughout the construction process. 

“Carlson had outgrown its previous location and needed a new, modern facility to facilitate future growth,” says Joe Ahrens, Market Lead of PREMIER’s Midwest Region. “Our team was committed to helping Carlson execute its vision for a new headquarters that would serve the company’s needs for years to come.”

Essential Elements for Production

Pure water is a key ingredient for nutritional supplement production. To ensure water quality, PREMIER installed a reverse osmosis system in both buildings, which purifies water using a series of filters. 

The reverse osmosis system processes water used in the misting and humidification system installed in the laboratory, ensuring moisture in the air is 100% pure as well. Misting and humidification systems keep all ingredients and products at the correct humidity levels–an important factor for supplements like fish oil, which include ingredients that need to be kept in a highly controlled environment. 

The project also included installing new HVAC and racking systems in the warehouse, as well as adding a clean-up area, processing room, assembly and packaging area, and storage room. In the two-story building, PREMIER added office spaces, a research and development lab, a labeling area, a dock door, and two roll-up doors with a connecting vestibule. 

Renovations Require Problem Solvers

Renovating older buildings requires a high level of adaptability as obstacles commonly arise during construction that were hidden during the planning process. During this project, complications emerged with the fire suppression system and roof, along with the need to find an Americans with Disabilities Act (ADA)--compliant elevator to fit the machine room design. PREMIER was able to pivot quickly to remediate complications and keep the project on schedule.

“We go into every project with a plan, but know we will have to switch gears and make adjustments as construction progresses,” says Bill Malarski, Senior Project Manager at PREMIER. “We’re a group of problem solvers and pride ourselves on being able to find options to address challenges that will lead to a successful project.”

Through the strength of PREMIER’s network, a team of trusted subcontractor partners and vendors was assembled to answer the project’s unique needs. Working with the right construction team that balances costs without sacrificing quality can help clients mitigate the impact on the budget when inevitable scope additions arise. As challenges emerged, they became opportunities for PREMIER to demonstrate its problem-solving expertise, ensuring the obstacles never became barriers for Carlson.

The team was prepared to act when they found a leak in the fire suppression system that ran from a pond to both buildings plus a neighboring third building. PREMIER replaced the entire system, updating it and tying the new piping into the city water supply instead of the pond, resulting in safe and reliable fire suppression using clean water. When it was determined that the existing warehouse roof could not handle the new laboratory’s equipment needs, construction of a new roof was added to the scope to accommodate the extra weight, providing long-term reliability without the need for maintenance or replacement for decades. 

Having a diverse range of thinkers and problem solvers is crucial for navigating complex projects. This was evident when addressing a previously unused and outdated elevator shaft. The original building was constructed in 1980 before the ADA was enacted in 1990. The PREMIER team was tasked with finding a manufacturer that could provide an ADA-approved elevator that fit in the empty shaft originally designed for a machine room elevator. Today, most elevators are machine room-less and 3 feet to 5 feet taller than a typical ceiling. 

To install a modern machine room-less elevator, PREMIER would have needed to raise the ceiling height–a cost- and labor-intensive add-on. Instead, the team decided to adapt and use a manufacturer that could provide an elevator designed for a machine room that would fit in the space. 

By effectively collaborating with our client and subcontractors, PREMIER was able to find the most advantageous solutions for Carlson. The team was continuously available to help the owners make decisions and understand how those decisions would impact the budget and schedule. 

Project Success

With open lines of communication and providing support throughout the design/build process, PREMIER delivered a modern headquarters that promotes new standards of excellence and will assist in continued growth for Carlson. 

Carlson and PREMIER celebrated the new production and lab facility during a grand opening event on Oct. 17. Two hundred and fifty guests joined the celebration, including Carlson employees and leaders, PREMIER leaders and the project team, the mayor of Lincolnshire, the local fire department, neighboring businesses and clients. 

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About PREMIER Design + Build Group

PREMIER Design + Build Group is a leading national design-build construction firm with regional offices strategically located in Illinois, California, and New Jersey. With a strong track record spanning 20 years, PREMIER specializes in providing comprehensive solutions for industrial, commercial, healthcare, residential, retail, and mixed-use construction projects. An employee-owned company, PREMIER has an unwavering commitment to quality, innovation, and customer service that has earned it a reputation as a trusted partner in the industry. For more information, visit www.pdbgroup.com.