End-to-End Food Factory Build and Fit Out

Client: Ferndale Foods (Oscar Mayer)

Duration: 4 Months

Location: Lincolnshire

Year: 2024

Value: 400,000

Overview & Objectives

Ambrey Baker was appointed as principal contractor to deliver a new-build food manufacturing facility for Ferndale Foods, part of the Oscar Mayer Group. The project included full civils, steel frame erection, a robust mezzanine floor, and floor-to-ceiling cladding.

The objective was to provide a high-specification food production environment, designed for durability, efficiency, and compliance with the strict standards of the UK food industry. Unlike many of our projects, this was not a live operational environment, allowing the works to progress smoothly without impacting ongoing production

Scope of Work

• Civil engineering works, including foundations, drainage, and external groundworks
• High-load mezzanine structure with concrete deck
• External building envelope and roofing package
• First fix mechanical and electrical infrastructure to support future process equipment

• Full structural steel frame supply and installation
• Floor-to-ceiling food-safe insulated cladding system
• Food-safe wall, ceiling, and door systems

Challenges & Solutions

Precision Engineering

The mezzanine structure required exact tolerances to safely accommodate food manufacturing loads. Our engineers delivered a perfectly level finish using laser-controlled installation techniques, ensuring strength, safety, and long-term reliability.

Efficient Programme Delivery

Although not live, the programme was still tightly controlled. Careful sequencing of civils, steel erection, and cladding meant that trades could progress without interruption, reducing downtime and maintaining momentum.

Future-Ready Design

Oscar Mayer required flexibility for future production changes. The facility was built with open spans, clear headroom, and adaptable M&E infrastructure, ensuring the site can be reconfigured quickly as operational needs evolve.

Outcomes

Ambrey Baker successfully handed over a new-build food production facility, complete with mezzanine, hygienic finishes, and a durable external envelope. The completed building provides Ferndale Foods with:

• A modern, efficient food manufacturing environment
• Long-term operational durability
• Flexibility for future expansion and reconfiguration
• Compliance with food hygiene and safety standards

This project highlights Ambrey Baker’s expertise in food factory construction and fit-out, from civil works and steel installation to mezzanine delivery and food-safe cladding. The facility is now a valuable asset to Oscar Mayer’s UK operations, supporting large-scale, efficient food production.