A former manufacturing site transformed into a modern chocolate production facility.
The GCB Cocoa Production Facility in Suffolk is divided into two sections known as the Chocolate and Cocoa buildings, under GCB ownership, with additional facilities including plant spaces and a security gatehouse. Previously used for producing baby bottles, the site transitioned to chocolate production, utilising separate lines for white and dark chocolate - the oldest part of the site focusing on cocoa refining, and the newest on chocolate manufacturing.
The site was developed for Clegg Food Projects, providing a modern, purpose-built facility that contributes to community support through local job opportunities. It stands out for its vertically integrated supply chain and traditional liquid manufacturing processes, alongside a diverse array of solid chocolate products - a notable advancement in the chocolate production industry. Although the works concentrated on the Chocolate building, the design accounted for future phase developments in the Cocoa building, ensuring provisions for service integration from the outset.
MEP design carried through every stage, from concept to operational readiness.
Osborn Associates delivered the building services design across the full project lifecycle. At RIBA Stage 2, initial design concepts focused on the facility's layout and the production lines for chocolate manufacturing. Stage 3 refined those concepts, detailing the spatial organisation and the integration of the cocoa processing machinery into the building services design.
At Stage 4, the final design documents were prepared, setting out the technical specifications for construction compliance and efficiency. Through Stages 5 and 6, construction was executed with close oversight from the company's engineers, leading to the facility's handover ready for cocoa production operations - an approach that ensured the project progressed efficiently from design to operational readiness.
Keeping a complex conversion on course through an extended programme.
Converting an existing manufacturing site around specialist food production machinery is a coordination-heavy undertaking, and the construction of the facility exceeded its planned duration. Osborn Associates ensured the on-site team had the support needed to coordinate effectively with all parties involved throughout the extended period.
By facilitating solutions and clarifying key points as they arose, the company was instrumental in overcoming the challenges and delays - maintaining progress and seamless collaboration through to the project's eventual success.
