Our Work
Here are some examples of our work. Click the images to learn more about each project.
Sausage production & company HQ development
New build multi species abattoir
Innovation centre
Ready meals production
Bakery ingredients processing, storage and head office development
Ingredient import and primary process facility
Vegetable processing
Bakery various sites
Cereal processing site
Sausage production & company HQ development
New build project designed from first principles and delivered through to production start-up.
Our client was experiencing rapid brand growth necessitating a move to a new purpose-built site. Our initial works were to develop a brief and to carry out process modelling to ensure the new facility met initial projected throughputs with scope for further growth, but without being uneconomical in the short term. The site was located in greenbelt and the brief called for a design which while functional also provided an aesthetically striking building that was sensitive to its rural setting. Our design also encompassed the repurposing of existing redundant agricultural buildings to form a future visitor centre.
The finished facility includes ambient, frozen and chilled storage, production and packaging areas, recessed loading bays and a full ancillary first floor of staff welfare, offices etc. The project also required diversion of existing high voltage infrastructure for the site and the formation of an infiltration drainage system for surface water and primary treatment for foul.
New build multi species abattoir
An extremely challenging project for which a design had been produced by a practice with little food processing experience. Once tendered for construction the original design came in at more than double the client’s budget. The site had level changes in excess of 9m, listed structures, a partially open and partially culverted watercourse and a large diameter 6m deep public sewer crossing diagonally through the full site. Additionally, the site had previously been backfilled with various waste material meaning that ground supported structures could not be developed.
Starting afresh we developed a design which overcame the numerous site constraints and worked with the topography. The design included innovations which challenged accepted conventions and ultimately delivered a facility which exceeded the original brief requirements and met the construction budget. Programme was truncated by the needs of grant funding and the client’s deadline to move to the new premises.
Innovation Centre
A project which commenced with very little in the way of a defined brief. We worked with the client to gather information and develop a brief and budget. The project comprised a self-contained product development and innovation centre. Facilities included cooked and frozen kitchens, walk in chilled frozen and dry ingredients storage, offices, presentation suites and staff facilities.
Bespoke furniture was designed to suit the clients functional and aesthetic brief.The site was comprised of existing ancillary facilities at first floor level of a live production site, surrounded by offices. Access was limited by size of existing goods lift meaning all materials and equipment had to be designed in a modular format.
Ready meals production
Designed as a phased site development achieving a long-term throughput target but with each phase standing alone and providing its own ROI. The site produces ready meals and includes high and low risk production areas with various cooking processes.
In addition to cooking we provided goods in/ out loading facilities, chilled storage, dry goods. The existing facility had to remain in production with no risk to product integrity and required extensive internal alterations to deliver the new site layout.
An extensive drainage system was designed which included on site effluent treatment.
Bakery ingredients processing, storage and head office development
A large project encompassing goods in, raw materials storage, production, finished goods storage and dispatch and a large head office and staff amenities facility.
The project required works throughout the live production site and due to proximity of residential properties a sensitive approach was required liaising with the planners and community. Due to the scale and complexity of the project and neighbouring residential properties we utilised 3D modelling capability to integrate the new structures into the existing site. We were also able to produce realistic renders of the site showing the phases of development.
Technically the project was complicated by the age range and varied construction types of existing structures, some of which had numerous floor levels both above and below ground, and onerous fire protection requirements.
Ingredient import and primary process facility
We had worked with this client for a number of years evaluating possible locations for new raw material import facility. Key criteria were identified including port facilities, high bay warehousing, extensive yard and good access links to motorway network.
A site was selected and procured which comprised an existing racked warehouse and basic ancillary staff facilities and a separate office building. No as built information existed so we began by carrying out a full survey of the site.
The proposed primary process was unique, and we worked closely with the equipment manufacturer to develop the solution and to integrate it into the site. A large extension was required to lift the roof height of part of the building, and to provide a safe deliverable solution we designed and constructed the extension as a completed pod at ground level built on a specially designed jig to mimic the building roof pitch. This was then craned onto the existing roof as a finished fitted out structure. The works included other extensions, new office, M&E and on-site effluent treatment
Vegetable processing
This project was located in a unique coastal location within the footprint of a former quarry. As part of the scope we removed a large section of the old quarry face and crushed this on site to provide high-quality low-cost subbase.
Two new portal framed structures were designed and constructed to provide an environmentally controlled storage unit and a grading/processing unit.
Pumped drainage was provided to deliver effluent to the existing on-site treatment. The processing unit was designed with large areas of glazing to provide natural light to assist with QA and provide enhanced operator comfort.
Bakery various sites
We have worked with this client across a number of their sites and a range of projects from refrigerated storage, rapid freezing, bakery production, NPD etc. All projects have been in live production sites typically in 24/7 operation.
As with all our client’s safety is paramount, which includes product integrity and for this client we have delivered projects with elements such as roof replacement, excavation of floors and drains, demolition, installation of full new production lines etc.
Cereal processing site
We came to this project quite late with a design having been produced and the client looking for a project management team to deal with tendering and delivery of the construction phase.
In providing a bid for this it became clear to the client that we should be asked to review the design. We did this and having identified a number of significant issues and opportunities we were appointed to re-design the project. We carried this out, then tendered and project managed through to delivery and commissioning.
This included not only new build but also works to existing live site and the installation of the process plant which the client had procured directly.