The investment follows growth for Unilever’s UK food business division and aims to support this uptick in demand, with a focus on driving supply chain efficiencies, boosting capabilities and delivering significant production growth at the site.
Now, after five years, the work has been completed, bringing with it a second factory built alongside the existing Burton site, a raft of new tech and automation, and 160 new jobs.
The construction of the new factory has increased the site’s footprint by 50% - which now stretches across 31,000 sqm and nine production lines, as well as bringing Hellmann’s to the site alongside Marmite, Bovril and Colman’s.
Investment in digital capabilities has been a big part the project, with the new factory equipped with automated production lines that use real-time data capture and analysis on the factory shop floor to boost efficiency and minimise waste.
The increased use of real-time data analysis at the site has helped to halve the site’s food waste since 2021 with the remaining waste redistributed, including to create energy for the factory via the on-site biogas recycling plant or feed for local farm animals.
Efficiencies were also gained by bringing the final stage of production for Hellmann’s 100% recycled plastic squeezy bottles – which sees the material blown into full-sized bottles – onto the site. This localisation of the brand’s packaging and production means that the number of lorries on the road and travel time from production to shelves have been reduced.
The new factory also boasts a fully automated palletisation process, with two robotic arm palletisers and three top loading palletiser robots that pack more than 1,000 pallets a day.
3D-printing machines and capabilities have also been brought in-house so standard machine parts can be replicated and replaced at speed.
According to Unilever, the investment across the two sites has propelled volume growth, which has doubled, alongside pushing up factory efficiency by 13%, over the last three years.
Now the Hellann’s production line is complete, Unilever expects 2024 to be a record year for the factory, with the site producing an average of 9m jars and bottles of condiments a month.
“By bringing all our condiment production under one roof and focusing on advancing digital capabilities, we’ve really optimised our supply chain and manufacturing whilst significantly increasing the site’s capacity. The investment has already delivered record breaking growth for the site and will be key in supporting the continued growth of our food business and market leading brands here in the UK,” commented Andre Burger, Unilever UK & Ireland foods lead.
“This investment is a celebration of our history in Burton as well as a commitment to its future. It is testament to the continued commitment and expertise of our teams at the site that its transformation has delivered such incredible growth so quickly.”