How to Scale Your Manufacturing Business: Space Requirements at Every Growth Stage
Is your manufacturing business outgrowing its space? Understanding your facility needs at each growth stage is crucial for seamless expansion. This guide breaks down exactly what to look for as your company evolves.
Startup Phase: 0-5 Employees
Typical Space: 500-2,000 sq ft
At this stage, you need flexibility without breaking the bank.
What to Look For:
- Flex spaces with minimal modifications needed
- Month-to-month leases, when possible
- Shared utilities to minimize overhead
- Basic loading access for smaller shipments
- Standard power (100-200 amp service)
Quick Tip:
Consider shared manufacturing spaces or incubators where you can access expensive equipment without the full investment.
Real Example: ABC Metalworks started in a 1,200 sq ft shared space, using communal equipment while establishing their customer base.
Early Growth: 5-20 Employees
Typical Space: 2,000-10,000 sq ft
Your production is more established now, with defined processes and increasing orders.
What to Look For:
- Dedicated production areas
- Small office space for admin work
- Proper shipping/receiving area
- Increased power capacity (200-400 amp)
- Basic climate control, if needed
Quick Tip:
Negotiate lease terms with expansion options built in. Your growth might happen faster than expected!
Real Example: XYZ Packaging secured a 7,500 sq ft facility after landing their first major contract, enabling them to triple output within 18 months.
Mid-Size Operations: 20-50 Employees
Typical Space: 10,000-30,000 sq ft
Efficiency becomes critical as you balance growth with operational costs.
What to Look For:
- Optimized workflow layout
- Enhanced loading facilities
- Dedicated quality control areas
- Expanded office space
- Higher ceilings (18-24 ft)
- Heavy-duty power (400-800 amp)
Quick Tip:
This is when proper warehouse management systems become essential – invest in them before space issues become bottlenecks.
Real Example: Midwest Electronics moved to a 25,000 sq ft facility with specialized zones, reducing production time by 35% through better layout design.
Established Enterprise: 50+ Employees
Typical Space: 30,000+ sq ft
Large-scale operations require sophisticated facilities tailored to your specific needs.
What to Look For:
- Custom-designed production facilities
- Multiple loading docks
- Specialized storage solutions
- Advanced climate controls
- Heavy-duty infrastructure
- Employee amenities (break rooms, etc.)
Quick Tip:
Consider build-to-suit options for highly specialized manufacturing requirements.
Real Example: Superior Manufacturing retrofitted a 75,000 sq ft former distribution center with dedicated cells for each product line, doubling production capacity.
5 Key Questions Before Your Next Move
Before signing a new lease, ask yourself:
- Growth Projection: Will this space accommodate your 3-year growth plan?
- Workflow Analysis: Could reconfiguring your current space delay the need to move?
- Location Factors:
- Can your workforce easily commute here?
- How will this location affect shipping costs?
- Are key suppliers nearby?
- Financial Strategy:
- At what point does buying make more sense than leasing?
- Are there tax incentives available in this area?
- What infrastructure modifications will you need?
- Future Technologies:
- Does this space allow for automation implementation?
- Can the electrical system support newer equipment?
- Is there room for sustainable upgrades?
Finding Your Perfect Manufacturing Space
When you’re ready to scale up, follow these steps:
- Work with specialists who understand manufacturing needs
- Tour multiple properties before deciding
- Bring your operations team on site visits
- Create a detailed requirements checklist
- Factor in build-out costs when comparing options
Your Next Steps
The right manufacturing space isn’t just four walls and a roof—it’s a strategic asset that can drive efficiency, quality, and growth.
Whether you’re looking for your first dedicated facility or planning a major expansion, WareCRE can connect you with industrial property owners who offer the perfect space for your production needs.
Ready to find the ideal space for your manufacturing business? Search available WareCRE properties to see options matching your current and future requirements.
