Spartan Logistics Case Studies

Lima, Ohio Location

Overview

When a long-standing customer identified a new opportunity in Lima, Ohio, Spartan Logistics responded promptly and precisely. Spartan transformed an underutilized facility into a fully operational, food-grade distribution center in just three months.

“The Lima operation reflects our ability to scale with our customers while maintaining performance, built on a foundation of strong partnership and operational alignment.” — Craig Recker, Vice President

The Goal

Spartan was tasked with securing and launching a distribution facility near the customer’s Lima production plant. Key objectives included:

• Sourcing a facility between 80,000–100,000 square feet
• Ensuring proximity to the plant for efficient product flow
• Designing a layout capable of supporting high-volume throughput
• Delivering a food-grade operation on an accelerated timeline

The Challenge

The selected building met geographic and size requirements but required significant transformation to support operations.

Key obstacles included:

• Converting a non-food-grade facility into a compliant environment
• Removing structural barriers, including a large mezzanine and interior walls
• Upgrading lighting, electrical, and IT infrastructure
• Managing high truck volumes with limited existing yard space

“In a warehouse start-up, nothing runs perfectly. Every pallet moved, every late night, every problem solved under pressure, turning hard days into steady progress. Tough beginnings don’t break strong operations; they build them.” — Chuck Harrison, Director of Operations

Beyond the physical upgrades, the team also had to tailor operations to fit location-specific requirements, rather than relying on a one-size-fits-all approach.

Execution & Coordination
What made the Lima startup possible was how closely Spartan’s teams worked together from day one of the project. Our real estate team at NAI Harmon Group and construction team at Logan Creek, along with our operations team, weren’t waiting on handoffs.

They were working together, solving problems as they came up. That approach and ownership of the outcome allowed the team to move fast, stay aligned, and bring the facility online quickly without cutting corners on food safety, customer service, or execution.

“The Lima startup was a strong example of cross-functional execution, aligning people, processes, and infrastructure quickly to achieve operational stability while maintaining a high standard of service for our customers from day one.” — Bobby Morman, Operations Support Manager

Adaptive Problem Solving

As volumes increased, the team quickly addressed site limitations by developing a large gravel lot to support trailer storage and truck flow, demonstrating flexibility in real time.

Regional Support & Training

We deployed experienced team members from nearby operations to support startup activities, training, and process stabilization.

The Results

Within just three months, the Lima facility was fully operational and exceeding expectations. Today, the results look like:

• Scaling from ~20 to 41 daily loads, evolving into a 24/7 operation.
• Improving the customer’s supply chain efficiency by being located near the production plant
• Maintaining flexibility to support evolving customer demands
• Achieving an AIB score of 985 on the first inspection
• Expanding services beyond the original scope

Conclusion

The Lima facility demonstrates Spartan Logistics’ ability to turn complex challenges into high-performing operations quickly and effectively. Through strategic coordination, hands-on execution, and a strong culture, Spartan delivered a solution that supports both immediate needs and long-term growth.