Reconfiguring for efficiency and future growth

THE ASPIRATION
Streamlining a proud manufacturer’s future
As the UK’s leading dumper manufacturer, Thwaites had outgrown its historic Warwickshire site. Their production process had become inefficient, with overlapping workflows and storage constraints forcing products outside, risking damage and delays. To meet growing demand and modernise operations, Thwaites needed to reimagine their site layout and introduce new facilities, all while maintaining full production.

OUR RESPONSE
Masterplanning a live manufacturing transformation
We provided full multidisciplinary services, including Project Management, Architecture, Civil and Structural Engineering, Building Services Engineering, Town and Country Planning, Cost Management, Geotechnical, Principal Designer and BREEAM consultancy.

Our first step was understanding how Thwaites worked. Through on-site workshops and process mapping, storage was quickly identified as the main constraint, and we proposed a new 4,200m² facility to centralise it. However, limited space, Green Belt restrictions and the need to keep manufacturing running 6am–10pm daily made the redevelopment highly complex.

We developed a detailed phased strategy that reconfigured the entire site – including new access routes, test track, car parks and utilities – while prioritising health and safety. The masterplan introduced clearer zoning, stronger security and effective separation between pedestrian routes and the various vehicle movements, ensuring operations could continue safely throughout.

Our teams also navigated ecological constraints, such as great crested newt habitats, aligning works with ecological and seasonal restrictions. Close coordination and weekly look-ahead meetings kept every stage on track.

THE RESULT
A fully integrated manufacturing campus
The £12.5 million redevelopment provides Thwaites with a state-of-the-art, efficient layout. The new storage facility, reorganised circulation routes and improved infrastructure have created a safer, more productive environment ready for future expansion – all delivered while maintaining uninterrupted production.

THE LASTING IMPACT
Building resilience into British manufacturing
Thwaites now operates with a streamlined manufacturing flow, reduced handling and downtime, and a safer, more sustainable working environment. The project strengthens their long-term operational capacity and supports continued UK-based innovation in plant machinery.

Find out more about our multidisciplinary approach