Industrial Construction Edmonton | Polykar Manufacturing Plant

Expanding with Purpose and Partnership

When Polykar, a leading Canadian manufacturer of sustainable packaging, set out to expand its operations to Western Canada, they needed a partner who could deliver a state-of-the-art manufacturing facility that reflected their innovative and eco-conscious brand. 

Scott Builders proudly collaborated with Polykar and FarMor Architecture Inc. on this ambitious project: an 85,300 sq. ft. plant designed to house cutting-edge automation, on-site recycling technology, and a striking architectural design. From day one, the project was driven by collaboration, technical expertise, and a shared commitment to delivering a facility that would set a new standard for industrial construction in Edmonton.

A Facility Designed for Innovation and Sustainability

The new plant spans 85,300 sq. ft. over two floors and is one of the most modern manufacturing facilities of its kind in North America. Designed by FarMor Architecture Inc., the building features distinctive façade fins and a curved central staircase, inspired by Polykar’s plastic extrusion process. 

Inside, the layout integrates advanced robotics, automated production lines, and a dedicated recycling facility to reprocess plastic waste, aligning with Polykar’s mission to support Alberta’s circular economy.

Located in Edmonton’s Discovery Business Park, the facility positions Polykar to better serve Western Canada and U.S. markets while setting a high design standard for future developments in the area.

Tight Timelines, Harsh Winters, and Complex Technical Requirements

Building such a sophisticated facility came with its share of challenges:

• Aggressive Timeline: The project had to be completed within an 12.5-month schedule (April 2021 to March 2022) during pandemic-related supply chain disruptions.
• Technical Complexity: Housing specialized manufacturing and recycling equipment required precision engineering for the structure, utilities, and foundations.
• Cross-Provincial Coordination: With the client based in Quebec, the architect in Calgary, and the construction site in Edmonton, seamless communication and coordination were essential.
• Harsh Climate Conditions: Winter construction in Alberta required careful planning to maintain safety and productivity during extreme weather.

High Design Expectations: The distinctive façade fins and curved staircase demanded exceptional craftsmanship to meet the client’s vision for a visually striking, one-of-a-kind facility.

Collaborative Problem-Solving and Precision Execution

Scott Builders approached these challenges with a focus on collaboration and proactive problem-solving. The project was led by Dan O’Hara (Project Manager) and Henry Oomen (Site Superintendent), who worked closely with FarMor Architecture and Polykar’s engineering team through regular planning meetings and site reviews.

Key solutions included:

• Adaptive Scheduling: Early procurement of long-lead materials and phased construction planning kept the project on track despite supply chain issues.
  
  
• Technical Integration: The team coordinated closely with equipment suppliers to ensure proper installation of automated production lines and the recycling system, including reinforced foundations and specialized utility hookups.
  
  
• Value Engineering: By refining material choices and construction methods, Scott Builders delivered high-quality finishes while staying within the $7.7 M budget.
  
  
• Quality & Safety Focus: Skilled trades were guided to achieve the precision needed for the building’s unique architectural elements, while strong on-site safety practices kept the project incident-free.
  
  

On-Time Delivery and a Lasting Economic and Architectural Impact

The Polykar Edmonton facility was delivered on time and on budget, standing as a benchmark for industrial construction that blends technical excellence, sustainability, and striking design.

• Expanded Capacity & Innovation: The plant immediately boosted Polykar’s production capabilities and introduced cutting-edge automation and on-site recycling technology, positioning the company as a leader in sustainable manufacturing.
  
  
• Economic & Community Impact: The project created 50 new local jobs (expected to grow to 70), supporting Edmonton’s growing advanced manufacturing sector and contributing to the local economy.
  
  
• Architectural Landmark: Its distinctive façade and thoughtfully designed interior have made it a visual landmark in Discovery Business Park, where it “sets the standard for new construction,” according to Polykar leadership.
  
  
• Client Vision Achieved: By meeting operational, aesthetic, and sustainability goals, the facility fully reflects Polykar’s brand as an innovator committed to Alberta’s circular economy.
  
  
• Trust in Partnership: Delivered in just 18 months, the project highlights Scott Builders’ ability to manage technical complexity and maintain schedule discipline through collaboration and problem-solving.

Bringing Polykar’s Vision to Life, Together

The Polykar Industries Manufacturing Plant is more than a manufacturing facility – it is a symbol of innovation, sustainability, and the power of collaboration. For Scott Builders, it was an opportunity to demonstrate how teamwork, technical expertise, and a client-focused approach can turn a bold vision into reality.

Ready to build your next manufacturing facility project? Whether you’re a developer, business owner, or architect, Scott Builders is here to help you bring complex projects to life – on time, on budget, and with a collaborative partnership you can trust.

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