For 25 years Pack Edge has been providing packaging solutions for a wide range of industries including fresh seafood and critical medical supplies. As they grew over the years they had expanded into three different locations, an inefficient set up for the business. Working with the developer Northland Enterprises and Management Corp.(Northland), Pack Edge had the opportunity to become a tenant and build a new home for their business that would meet both their current and future business needs. PATCO Construction, Inc. (PATCO) has a history with Pack Edge, having designed buildings and additions for them over the past 15+ years. A strong relationship was also built over the years, which was one reason Northland CEO Josh Benthien was confident about working together to build a new industrial headquarters for Pack Edge on Northland’s industrial site. Northland, a developer with a reputation for being a leader in built-to-suit solutions for companies, had worked with some of Southern Maine’s leading construction management firms in the past. For this project, Northland needed a partner that would not only meet Pack Edge’s specific needs for an industrial building, but also help set the stage for further developments on their site. 

“It’s a simple warehouse building, but with a complicated infrastructure and process for Pack Edge,” shares Benthien. “We didn’t go out to bid. We knew if PATCO couldn’t build this for a number that made sense, no one could. They were by far the most cost-effective.” Pack Edge President Jim Freeman was equally confident about working with PATCO: “PATCO is very conscious on price. Their proposal outlines the true cost – that’s the price. There’s no surprises.” 

Working collaboratively with both Northland and Pack Edge, PATCO went to work to build a 46,000 square foot pre-engineered metal building, with room for manufacturing, storage, and a 3,000 square foot office area. It’s a particularly tall building to meet the new industrial standards and enable high-bay storage. An interesting and challenging feature of the project was the 7,500 square foot freezer, a huge, cavernous space essential for Pack Edge, who manufactures freezer gel packs. The freezer has a section to flash freeze the gel packs and another section of the freezer to store them. “I can remember the first freezer we bought,” shares Freeman. “We were in a tiny wooden building and we bought a little freezer that could hold three pallets worth of gel packs. Now we can store 900 pallets of gel packs in the new freezer.” A concern with such an enormous freezer is that it can act like permafrost, freezing the ground below. Specialized flooring was required. Freeman explains: “Thermal breaks were needed so the slab wouldn’t crack or expand. PATCO worked with freezer engineers like they were their own sub. Everyone was in the loop and everyone was on the same page.” Benthien was also impressed with PATCO’s proactive management of the complex situation. “They reached out to the freezer vendor so we could collectively understand what was required. We got a much better product and I sleep better at night.”

Another challenge for the project involved one of the previous owner’s tenants. A 94-year-old man lived on the property in a trailer. It was important to Benthien that the man be allowed to stay in his home so PATCO, along with the subs, found a way to work around the trailer. “We wanted to work with the previous owner on this. It was an extremely sensitive issue and it impacted efficiency. PATCO was super flexible and able to pivot and resequence things,” shares Benthien. “They did the compassionate thing. They were sensitive to the situation all while hitting the project goals and meeting our deadline.” 

The success of this complex project is due in large part to PATCO’s Design-Build Process, a framework that enables PATCO to develop a plan to manage project costs, schedule, and quality as the team creates a custom building design. Dennis Waters, Vice President at PATCO, was intimately involved in the Northland/Pack Edge project from the beginning and is a big advocate for Design-Build. “Our process takes the cost into account right from the design to make sure the build is feasible,” shares Waters. “We don’t want clients spending money going down a path that is not fruitful. We’re close to the ground, we’re building those buildings. We know what things cost and what things can be permitted. It’s a more streamlined and direct approach. My goal was to do a Design-Build project for Northland and let them know it would work out OK. They weren’t accustomed to working in this way. They took a risk working with PATCO.”

“PATCO worked differently than we’re used to,” shares Benthien. “They did exactly what they said they were going to do. We’re very happy with the project.” Benthien was particularly impressed with the collective debrief that PATCO led at the end of the project to go over what went well and what could be improved for the next project. “It was a nice way to wrap up the project,” says Benthien who was also quick to credit the project success to the team PATCO put together. “Any project success is 99% because of the team that works on it and PATCO put together a great team. Bob Coy, the supervisor, was tremendous. Dennis attended every meeting. They’re the reason for the success.” As with all PATCO projects, Dennis and the PATCO team reiterated that if there were issues in the future, PATCO would be there to help find a solution. For Benthien, that felt like an added value. “It’s more of a relationship than a transaction. We want to work with PATCO again.”

For Freeman, the project represents a huge milestone in the growth of the company. “PATCO has been instrumental in helping us grow. They built us a building that fit our needs and fit our budget. The building is big, it’s properly designed, and it is an asset for us in convincing customers we can handle their business.” 

 

PATCO Construction, Inc. Employee Spotlight

Greg Coombs

Commercial Project Coordinator

Greg Coombs joined the PATCO team in May of 2024 as a Commercial Project Coordinator, but has had a relationship with PATCO for over 15 years as a client. Prior to PATCO, Greg worked with NAPA Auto Parts and hired PATCO for many building projects over the years including a 8,500 square foot store in Bridgton. Born in Providence, Rhode Island, Greg moved to Maine when he was three years old and was raised in the Skowhegan area. After spending time working in Florida and California, Greg came back to Maine in 1991 and worked for NAPA for over 30 years, most recently as Maine District Operations Manager.

What is a typical day like for you?

I’m behind the scenes helping run a couple projects – there are some small projects for NAPA stores and a project for Barry Equipment in Gorham. I’m getting involved with the subs and getting them lined up, getting bids – it’s all new for me. 

 

Why did you join PATCO?

I’ve known Greg Patterson and Jon for a couple of decades now. After having a corporate life for the last 33 years it’s nice to join a small, private company that is interested in taking care of its employees. 

 

What is the best part of your job?

Learning. [Working at PATCO] is an entirely new experience for me and I’m constantly learning. If you’re not learning you’re not growing. 

 

What do you like to do in your free time?

Anything outside: yardwork, golf, tennis. My wife forces me to hunt. She hunts for anything that moves. I just enjoy being outside. We like to ATV a lot. We keep our 4-wheelers up at our place near Skowhegan. 

I have two grown daughters who live in Maine as well.