137,000 square feet. Six docks. Five production lines. Within 650 miles of 75% of America.
The FRS facility isn’t just where the work happens — it’s why the work happens as fast and as well as it does.
Every capability FRS brings to your supply chain challenge is only as good as the facility behind it. A skilled labor force needs space to work. Processing at scale requires infrastructure built for it. Fast turnaround depends on a receiving and shipping operation that doesn’t create bottlenecks. And storing millions of units of client inventory requires a facility that takes security and organization as seriously as throughput.
The FRS facility in Western North Carolina was built around those realities — and fifty years of operational refinement have made it one of the most capable processing environments in the region.
The facility by the numbers:
- 137,000 square feet of administrative and processing space — purpose-built for high-volume, multi-line processing operations
- 5 full-scale production lines capable of running simultaneously for concurrent job processing without resource competition
- 6 dock doors equipped for efficient inbound receiving and outbound shipping at volume
- 1.5 million units per week processing capacity — the throughput infrastructure to handle your largest and most time-sensitive jobs
- 40 to 50 million units shipped annually — the output of a facility that has been optimizing its operations for decades
- 8 million units securely stored on-site at any given time
These aren’t theoretical capacities. They’re the operational reality of a facility running at scale every week for clients across multiple industries and product categories.
Location — Built for National Reach.
Western North Carolina is not the first place most people think of when they think logistics hub. It should be.
The FRS facility sits at a rare convergence of three major interstate corridors — I-85, I-40, and I-26 — that together provide direct access to the Eastern Seaboard, the Southeast, the Midwest, and beyond. The practical result of that positioning is one of the most significant logistics advantages a processing partner can offer:
FRS is within 650 miles of 75 percent of the United States population.
For clients coordinating inbound shipments from manufacturers, outbound delivery to distribution centers, and direct-to-retail fulfillment across multiple locations, that reach means shorter transit times, lower freight costs, and delivery windows that are genuinely achievable rather than optimistic.
Your product arrives at our dock faster. It leaves for its destination faster. And the freight cost of moving it in both directions reflects a location chosen for logistics efficiency rather than coincidence.
Five Production Lines. No Bottlenecks.
The ability to run five full-scale production lines simultaneously is what separates a facility built for processing from a warehouse that does some processing on the side.
At FRS, concurrent production lines mean your job isn’t waiting for another client’s job to finish before yours can start. Multiple projects run in parallel — each with its own dedicated line, its own quality control process, and its own outbound timeline — without competing for space, equipment, or labor. When your deadline is Tuesday and another client’s deadline is also Tuesday, both shipments go out on time.
That concurrent capacity is particularly valuable for clients with multi-component jobs — kitting combined with labeling combined with ticketing combined with quality inspection — that benefit from parallel processing rather than sequential steps that add days to the timeline.
Six Docks. Inventory Moving Constantly.
Six dock doors means FRS can receive inbound shipments and process outbound deliveries simultaneously without the receiving bottlenecks that slow down facilities built around fewer access points. Your raw materials arrive, get counted in, and move immediately into processing — not into a staging queue waiting for a dock to open up.
For JIT clients coordinating precise delivery windows, that dock capacity is a critical part of the timing equation. Inventory doesn’t sit at the door. It moves.
Security and Organization — Your Inventory Protected.
Storing millions of units of client inventory is a significant responsibility and FRS takes it seriously. Our facility maintains a secure environment with controlled access, organized storage that allows specific inventory to be located and pulled efficiently, and the kind of clean, well-maintained operation that reflects how seriously we take the product our clients have trusted us with.
Your inventory is an asset. We treat it like one.
A Facility That Reflects Fifty Years of Refinement.
The FRS facility today is the product of five decades of operational learning — space allocated based on what actually works at processing scale, dock configurations built around real throughput requirements, and production line infrastructure developed through thousands of jobs across dozens of industries.
When you visit — and we encourage you to — what you’ll see is a facility that was designed for the work it does rather than adapted to it. That’s a distinction that shows up in your turnaround times, your cost per unit, and the quality of the finished product that ships from our dock to your retail partner.
137,000 square feet. Fifty years of refinement. Ready for your next job.