Saica – Hamilton, OH

Operations Underway at Saica Group’s First U.S.-Based Manufacturing Facility

After much anticipation, Saica Group’s first U.S.-based corrugated box manufacturing facility is fully operational. Cardboard boxes have been rolling off the line as construction of the 350,000 square foot facility officially wrapped up in February 2022.

Located in Hamilton, Ohio, the plant marks a $72 million investment for Saica Group, a global packaging company based in Spain. While REDI Cincinnati, JobsOhio, and the City of Hamilton were instrumental in bringing Saica Group to Hamilton, Miller Valentine Construction served as a trusted guide throughout the design and construction process.

Expert Guidance From Start to Finish

Saica Group specializes in manufacturing sustainable and innovative packaging solutions. The company operates dozens of facilities across Europe, the United Kingdom, and Turkey, but the Hamilton project marked its first entry into the U.S. market.

The company selected Miller Valentine based in part on our extensive portfolio in the paper and packaging industry. Drawing from our experience with international clients, we took the time to educate the owner about the inner workings of building on a greenfield site in the U.S.

“Recognizing that this was our client’s first experience with building in the U.S., we really dug in to ensure the Saica team understood the process from start to finish, giving them the information and recommendations to make educated decisions that were most impactful for their business,” said Hank Betts, Vice President of Business Development.

Forging Ahead Despite Disruption

From the moment the project broke ground in September 2020, it became a proving ground for navigating pandemic-related supply chain disruptions. The Saica project faced the predicament of numerous material shortages that swept across the country during 2020 and 2021.

Obtaining roofing material presented an especially difficult hurdle for the project team as a national shortage threatened to delay dry-in of the facility by nearly six months.  This posed a significant coordination challenge with Saica’s equipment deliveries.

“We went back to the drawing board, coordinating with all of our project partners and creating provisions to allow progression of mechanical, electrical, and plumbing installation, limiting the impact to the overall project schedule,” said Sean Looney, Assistant Project Manager for Miller Valentine. “Our goal was to advance the equipment framework as much as possible to expedite final connections and startup of production.”

Ultimately, the project team installed a temporary roof system until permanent materials could be acquired. The team also worked with Saica Group to source portions of the roofing system from Spain. This solution permitted the advancement of the process infrastructure and ensured a dry and safe location for the equipment upon arrival.

“Sourcing materials from another country is not something we have historically considered, especially material manufactured here in the US, but given the extraordinary circumstances, we had to explore all options,” said Hank. “By being highly adaptable to the obstacles presented and advocating for our client at every turn, we were able to minimize risk and disruption to the greatest extent possible.”

Big Impact Close to Home

The Saica Group Hamilton plant is expected to create more than 60 jobs upon full capacity. The company is already exploring opportunities to expand its U.S presence within Ohio and beyond. With an emphasis on sustainability and job creation, the company is looking to serve as both a good local and global citizen.

“Along with partners like JobsOhio and RediCincinnati, we’re invested in projects and companies that contribute to the growth of our local communities,” said Hank.  “Saica Group exemplifies those qualities and values, and we couldn’t be more proud to have built this global company’s flagship facility here in our region.”

Miller Valentine partnered with Phoenix Architecture, Advantage Engineering, Genesis Design, and Terracon Consultants on the project.

Building features include:

• Loadbearing concrete exterior construction
• 20,530 SF of office area, including lab and tech areas
• 10,777 SF, 70’ tall WIP Building
• Approximately 23,000 SF of mezzanine
• 14 docks
• 5 drive-in locations
• 87,000 SF finished goods storage