Thwaites Manufacturing Campus Expansion

Outgrowing its historic layout, Thwaites needed a safer, more efficient manufacturing campus – delivered without disrupting daily production.

We delivered interdisciplinary services across architecture, engineering, project management, cost consultancy, planning, sustainability and principal designer roles.

Masterplanning a live manufacturing transformation

We began by understanding how the site really operated. Workshops and process mapping revealed the core constraint: scattered storage was slowing movement, increasing handling and raising the risk of damage and delay. Our solution was a new 4,200 m² central storage facility, positioned to streamline materials handling and unlock flow across the campus.
Delivering this on a live site added complexity. The campus sits within the green belt, space was tight and production runs from 6am to 10pm. Stopping wasn’t an option.

We developed a phased strategy to reconfigure the site while keeping operations fully active. New access routes, a bespoke on site test track, reorganised parking and upgraded utilities were introduced in sequence. Clear zoning, safe pedestrian to vehicle separation and stronger security kept the site safe and the work uninterrupted.

We also navigated ecological constraints, including great crested newt habitats, timing works to seasonal windows. Weekly coordination and simple look ahead planning kept progress steady.

A safer, more efficient operation

The £12.5 million redevelopment has transformed how the site works. The new central storage hub reduces unnecessary handling and improves flow. Reorganised circulation eases congestion across the campus. Infrastructure upgrades support safer, smoother day to day operations. And crucially, production continued throughout.

Building resilience into British manufacturing

Beyond the physical changes, the redevelopment strengthens Thwaites’ operational resilience. With streamlined flow, reduced downtime and improved safety, the site is better placed to support future UK based innovation in plant machinery. The campus works harder for the business – and is ready for what comes next.