The meat snack industry just witnessed a major expansion as Archer, one of America’s fastest-growing clean-ingredient meat snack brands, officially opened its second manufacturing facility in Vernon, California. This strategic move represents more than just increased production capacity: it’s a testament to the explosive growth happening in the premium meat snack category and Archer’s commitment to vertical integration in an increasingly competitive food and beverage landscape.
Strategic Expansion Meets Soaring Demand
Located just outside downtown Los Angeles, the new 140,000-square-foot facility doubles Archer’s overall manufacturing capacity, positioning the company to produce over 36 million pounds of meat sticks annually: equivalent to more than 1 billion Archer Mini Sticks. This expansion comes at a pivotal moment for the company, which expects to surpass half a billion dollars in sales by the end of 2026.
The numbers tell a compelling story about Archer’s market position. While the broader $3.3 billion meat snack category grows at a steady 5.8% annually, Archer is experiencing a remarkable 90% year-over-year sales increase. Even more impressive, their meat stick sales have surged by 187.4%, making Archer one of the primary drivers of growth in the overall meat stick category.
“Opening this facility in Los Angeles, the city that has been integral to our growth story, is a major milestone for Archer,” said Eugene Kang, founder and CEO. “This expansion ensures we can meet increased demand for our meat sticks, while also setting us up for long-term category leadership by investing in our own infrastructure.”
Community Impact and Economic Development
The Vernon facility represents a significant investment in the Los Angeles community, adding more than 200 jobs to complement the existing 150 employees at Archer’s San Bernardino manufacturing plant. This expansion demonstrates how successful food and beverage companies can drive local economic development while scaling their operations.
The facility, previously operated by Farmer John for 90 years, has been transformed into a state-of-the-art meat processing and packaging operation specifically designed for Archer’s meat stick production. This strategic repurposing of existing infrastructure showcases efficient capital allocation while maintaining the facility’s historical significance in Los Angeles food manufacturing.
The “Stick to Real” Philosophy Drives Growth
Archer’s explosive growth stems from its unwavering commitment to clean ingredients and quality. The company’s “Stick to Real” philosophy positions Archer as the trusted choice for consumers seeking food made from real ingredients without compromising on taste or quality. This approach resonates strongly with today’s health-conscious consumers who are increasingly scrutinizing ingredient lists and demanding transparency from food and beverage companies.
The brand exclusively uses grass-fed and grass-finished beef and all-natural proteins, avoiding fillers, shortcuts, or ingredients consumers can’t pronounce. This commitment to clean labeling aligns perfectly with broader food industry trends toward transparency, sustainability, and premium positioning.
Manufacturing Excellence and Quality Control
The decision to maintain vertical integration through company-owned manufacturing facilities reflects Archer’s strategic focus on quality control and operational efficiency. By owning their production capabilities, Archer can maintain rigorous standards while responding quickly to market demands: a critical advantage in the fast-moving consumer goods sector.
The Vernon facility’s focus on meat stick production allows for operational synergies with the San Bernardino plant, which continues producing both jerky and meat sticks. This specialization enables enhanced training and development programs across both locations while optimizing production efficiency for different product lines.
Market Position and Distribution Strategy
Archer’s retail footprint spans over 30,000 stores nationwide, including major retailers like Costco, Whole Foods Market, Walmart, Starbucks, Target, and 7-Eleven. This extensive distribution network provides the foundation for leveraging increased production capacity from the new Vernon facility.
The company’s partnership with the Los Angeles Dodgers as their official meat snack partner further solidifies Archer’s connection to the LA market and demonstrates the brand’s confidence in its local manufacturing presence. This type of strategic partnership reflects sophisticated marketing approaches that resonate with regional consumer bases while building brand awareness.
Industry Implications and Future Outlook
Archer’s expansion reflects broader trends shaping the food and beverage industry. The meat snack category continues benefiting from consumer trends toward protein-rich, convenient, and clean-label snacking options. As busy lifestyles drive demand for portable nutrition, companies that can scale production while maintaining quality standards are positioned for continued growth.
The company’s focus on clean ingredients and premium positioning also aligns with the growing influence of health-conscious millennials and Gen Z consumers who prioritize product transparency and are willing to pay premium prices for quality. This demographic shift creates sustainable growth opportunities for brands that authentically deliver on clean-label promises.
Manufacturing Technology and Innovation
While specific details about the Vernon facility’s technology weren’t disclosed, the emphasis on state-of-the-art operations suggests significant investment in modern manufacturing capabilities. In today’s competitive landscape, food and beverage companies increasingly rely on advanced production technologies to maintain quality consistency while achieving operational efficiencies at scale.
The ability to produce over 1 billion Mini Sticks annually from a single facility demonstrates the importance of production optimization in meeting consumer demand. For food service industry professionals, this type of capacity planning provides insights into scaling operations while maintaining product quality standards.
Competitive Landscape Analysis
Archer’s 187.4% growth in meat stick sales significantly outpaces category averages, indicating successful differentiation in a crowded market. This performance suggests that premium positioning combined with clean ingredients can drive substantial market share gains, even in mature categories.
The company’s vertical integration strategy also provides competitive advantages through improved margins and supply chain control: critical factors for food and beverage companies navigating volatile commodity costs and supply chain uncertainties.
Looking Forward
As Archer positions itself for continued growth, the Vernon facility expansion represents a foundation for long-term category leadership. The company’s commitment to Los Angeles manufacturing, combined with its clean-ingredient philosophy and strong retail partnerships, creates a compelling platform for sustained growth in the evolving meat snack landscape.
For food and beverage industry professionals, Archer’s expansion story offers valuable insights into scaling premium brands, the importance of vertical integration, and the power of authentic brand positioning in driving consumer preference and retail success.
Written by Michael Politz, Author of Guide to Restaurant Success: The Proven Process for Starting Any Restaurant Business From Scratch to Success (ISBN: 978-1-119-66896-1), Founder of Food & Beverage Magazine, the leading online magazine and resource in the industry. Designer of the Bluetooth logo and recognized in Entrepreneur Magazine’s “Top 40 Under 40” for founding American Wholesale Floral. Politz is also the founder of the Proof Awards and the CPG Awards and a partner in numerous consumer brands across the food and beverage sector.
