Based on an interview with Bill Seretta, Executive Director
A Vision Takes Shape
In the heart of South Portland, ME, Fork Food Lab stands as the state’s only non-profit food business incubator and shared manufacturing facility. As a hub for over 80 food entrepreneurs, this shared kitchen offers a space where culinary dreams take flight. The shared kitchen was first built in 2016, but as demand grew, so did the need for a larger facility. Fork Food Lab’s journey from a modest space in the West Bayside neighborhood to a sprawling 18,000-square-foot facility in South Portland is a story of vision, perseverance, and strategic planning.
Facing Challenges in the Original Space
Fork Food Lab’s original home, a two-story building in Portland, was full of character but fraught with challenges. The building’s inconsistent temperature control disrupted food production, while an inadequate hood system left the air quality lacking and workers uncomfortable. The absence of a dedicated bakery area stunted the growth of that segment of their membership. Parking was limited, a common issue in urban spaces, which hindered member activities and events. Moreover, the street loading system was inconvenient, leading to frequent disruptions in operations. The dish pit, essential for maintaining cleanliness, was inefficient and guzzled water, adding to operational headaches. Despite these obstacles, the demand for Fork Food Lab’s services grew, signaling it was time for a significant change.
The Move to South Portland
By Summer 2022, Food Fork Lab decided to relocate to a larger space in South Portland—a move that would double their capacity and allow for future expansion. The new facility, a 30,000-square-foot building, offered the canvas Fork Food Lab needed to reimagine its operations. extra cost, enhancing operational efficiency. Private, lockable kitchen spaces, or pods, were in high demand, leading to a waiting list. Introducing a new dishwasher system reduced water usage significantly, aligning with Fork Food Lab’s commitment to sustainability.
Phase 2: Expanding Revenue Streams
With phase one completed, Fork Food Lab turned its attention to phase two: generating additional revenue streams while serving the community. This phase involved demolishing and building a 12,000-square-foot area to create event space and a pop-up restaurant, complete with parking for 120 cars and an 18-wheeler loading dock. Food Fork Kitchen added a 4,500-square-foot USDA-spec food processing area, catering to local businesses engaged in fruit, vegetable, and meat processing. Additionally, Fork Food Lab introduced co-packing services modeled after successful ventures in Western Massachusetts, and a new 2,500-squarefoot palletized freezer space was built for long-term warehousing.
The relocation was not without its challenges. The renovation alone cost between $10 million to $15 million, a figure driven higher by steep interest rates and unexpected delays. However, with strategic fundraising and effective financial management, Fork Food Lab was able to navigate these challenges and focus on the future.
Phase 1: Laying the Foundation
The first phase of the expansion, completed in June 2023, was a leap forward. Forty-two companies moved into the new 18,000-square-foot operational space, bringing the total membership to 85 by the summer of 2024. The new facility replicated the original model but with significant improvements. Cold storage capacity increased fourfold, walk-in freezers were expanded to 19,000 square feet, and members now had access to specialized equipment at no Fork Food Lab (2021). extra cost, enhancing operational efficiency. Private, lockable kitchen spaces, or pods, were in high demand, leading to a waiting list. Introducing a new dishwasher system reduced water usage significantly, aligning with Fork Food Lab’s commitment to sustainability.
Looking Ahead: Sustainability and Growth
Fork Food Lab’s expansion is not just about increasing capacity; it’s about creating a sustainable future. The new facility will generate income through event hosting, co-packing services, and freezer space rental. But beyond financial growth, Fork Food Lab is committed to minimizing its environmental impact, with plans to install solar panels and continue its energy-efficient practices.
Key Takeaways
The expansion of Fork Food Lab is a testament to the power of strategic planning, adaptability, and having a clear vision for the future. By learning from the challenges of their original facility and implementing a phased approach to expansion, Fork Food Lab has positioned itself as a leader in the shared kitchen industry. The new facility supports its members’ growth and reflects a deep commitment to sustainability and community impact. As Fork Food Lab looks to the future, it stands as a model of innovation and resilience, ready to support the next generation of food entrepreneurs.
