Charlotte’s Web Cannabinoid Production Facility

Industry leader expands production capabilities for cannabinoid extraction and laboratory operations

As an industry leader, pioneer, and visionary of the cannabinoid industry, Charlotte’s Web has experienced rapid growth and market share. Production capacity proved to be a limiting factor, however, and expansion was necessary to keep up with demand and new product development. Additionally, Charlotte’s Web housed its warehouse operations and production facility in separate locations in the Denver metropolitan area.

This project allowed for expansion of warehousing, increasing efficiency through larger capacity, upgraded supporting utilities, and centralized business-to-business (B2B) and business-to-consumer (B2C) distribution. The three-phase effort was built out within a new 135,000 square foot building in Louisville, Colorado, and includes warehouse operations, production employee offices, and production spaces. Larger-scale production with supporting research and development (R&D) and quality control (QC) laboratories allows for close control of operations. Consolidation of these facilities allows Charlotte’s Web to realize efficiencies in both production and distribution.

Raw materials bulk storage and handling are key components of facility operations. This includes raw hemp, bulk oil, and spent hemp handling. Lab gases, steam, chilled water, and compressed air are now in-house utilities supporting operations. Bulk tanks and centralized boiler, lab gases, chiller, vacuum, and compressed air yield previously unattainable operational efficiencies. The seamless flow of raw materials and finished products from production to QC to warehouse distribution operations is an essential component of efficiency and quality control.

What We Did

The new facility allows for the production of CBD manufacturing in two extraction trains. Each method includes full scale as well as pilot scale production for R&D. For the expansion, Gannett Fleming provided an initial Basis of Design (BOD) to align client expectations with the design and construction path. Full engagement of each team (design, construction, client) was critical for early deployment of construction and thorough design.

Beginning with the warehouse phase, the client was able to begin operations in this space as the construction of the second phase offices were underway. The offices were occupied during the construction of the production phase. This approach allowed the client to exit their previous facilities earlier, reducing operating costs. Current good manufacturing practice (CGMP) spaces, hazardous rooms, and clean manufacturing spaces were all included in the design and construction of the facility. Laboratories were outfitted with fume hoods, including lab gas connections for research and development, analytics, and quality testing.

Key Features

  • 50,000 square feet of warehouse space for B2B and B2C distribution and 3,000 square feet of offices.
  • Quality control and research and development labs allow in-house analytics.
  • 15,000 square feet of office space with main entry lobby, gymnasium, and versatile office seating.
  • 70,000 square feet of production space with redundant operating capacities and future expansion capabilities.
OUTCOMES

Multi-method cannabidiol extraction trains.

Bottle filling, packaging, and warehousing capabilities.

Design supports future expansion within the facility.

Internal laboratory research and quality testing capabilities.