Westrock Coffee’s Arkansas plant in Conway, built with a $315 million investment, spans 525,000 square feet and churns out millions of single-serve coffee pods daily. The facility’s innovations include advanced robotics and end-to-end automation, streamlining production from raw coffee beans to sealed packaging. This integrated approach guarantees rapid output while maintaining quality. The Coffee Lab’s Q Grading system employs certified experts to conduct daily sensory evaluations, identifying defects like mold or overfermentation while scoring beans for optimal roast profiles. The onsite Research and Development lab enables real-time collaboration between Westrock’s scientists and client teams to refine beverage formulations. Adjacent warehouses and a separate 530,000-square-foot distribution center two miles away enhance efficiency, cutting transport time for products headed across North America. These advancements solidify its status as the continent’s largest roast-to-ready-to-drink manufacturing site.
The plant’s economic benefits ripple through central Arkansas, with plans to employ 900 skilled workers once fully operational. Jobs range from machine operators to logistics specialists, reinforcing the local workforce. The facility’s location in a former Kimberly-Clark paper plant capitalizes on low utility costs and proximity to Interstate 40, reducing overhead. Its closeness to Westrock’s Little Rock headquarters also guarantees tight coordination.
Conway’s emergence as a coffee manufacturing hub aligns with Arkansas’ broader push to attract high-value industries. Currently operating at 75% capacity, the plant aims to hit full production soon, running five-day shifts to meet surging demand for single-serve pods. The global market for these products hit $35.3 billion in 2024 and could double by 2034.
Westrock’s automated systems allow it to scale swiftly, supplying major retailers and coffee brands. The 130,000-square-foot manufacturing floor focuses solely on pods, while the rest of the facility handles storage and distribution.
Strategic site selection played a key role. Arkansas’ central location and existing infrastructure simplify nationwide distribution. Low energy costs give the company a financial edge, while repurposing an older industrial site minimized upfront expenses. Westrock’s growth mirrors trends toward convenience-driven coffee consumption, positioning it as a leader in beverage innovation.
With expansions already hinted at, the Conway plant could anchor further regional economic development.
