• Client: Barry Callebaut
  • Sector: Manufacturing
  • Project: Factory Expansion
  • Location: Banbury
  • Value: £5m
  • Form of Contract: JCT 2016 with Quantities form of Contract

Barry Callebaut Chocolate Factory, Banbury

Barry Callebaut is the world’s leading manufacturer of high-quality chocolate & cocoa products, with an average sales of 2,139,758 tonnes tonnes of chocolate and cocoa products (2018/19). Their products are present in one out of four of all chocolate and cocoa products consumed around the world.

The Project

The contract was secured following a single stage competitive tender process, and the award was partly due to the successful completion of an initial enabling works package where our diligent approach throughout was appreciated by the Client.

O’Brien were engaged as Principal Contractor on a JCT 2016 with Quantities form of Contract to carry out phased major alteration and refurbishment works to Barry Callebaut’s existing production facility at Banbury, along as the construction of an extension and new standalone building that would enable the factory to increase its production by circa 20%.

Our construction operations were carried out within a live manufacturing environment with a busy delivery and loading operation at the production facility.  We put in place a carefully controlled and stringent programme, phasing the works to ensure that manufacturing and deliveries on site were not uninterrupted.

All works were carried out in accordance with strict hygiene procedures with detailed practices being adhered to, along with specialist plant and equipment being utilised to ensure that there was no contamination to the food manufacturing process.

Building Alteration and Upgrading Works for New Tank Farm Installation

 The tank farm alteration and refurbishment works included the installation of ducting systems, lighting, smoke detection and distribution panel.  Full decoration, new flooring, and new high-level steel access walkways to the existing structure.

Additional works included piled foundations to take the load of the new product tanks which would hold the liquid chocolate as well as the erection of new steel work to strengthen the existing structure in preparation for the installation of crane beams.

Tank Farm Delivery Yard Construction and Road Construction

Construction of a new in-situ concrete yard and access road to the side and the rear of the ‘Tank Farm Building’.  Works included a new steel frame and canopy to a loading dock area with the structural steelwork being simultaneously lifted into place by 3no 75 tonne mobile cranes.

Along with canopy dock levellers were installed to act as loading bays for delivery vehicles. An adjacent building was refurbished with new doors and windows and provide welfare for employees.

Production Area Extension and Refurbishment Works

A 500m2 structural steelwork and composite clad extension was constructed to the current production area to enable the client to increase capacity and fitted out with a food safe internal ceiling along with high level steel access walkways.

The refurbishment works included drainage diversions, breaking out of the existing floor slab, installation of new concrete bases associated with the new extension. Installation of a new mechanical ventilation system and resin floor

 New Standalone Utilities Building

 A new standalone utility building was constructed that houses electrical plant and equipment which will be used to pump product ingredients into the main manufacturing facility.

Prior to construction of the 520m2 steel clad building a McCann pre-cast concrete retaining wall was erected to the exterior of the building.

The in-situ concrete floor slab to the building included machine pits and plinths. M&E installation included earth matting, smoke detection, lighting protection, small power, and mechanical ventilation, as well as all drainage and ducting works.