Kara’s recent investment into its foodservice site exemplifies the manufacturer’s strategic vision to expand within the out-of-home and wholesale bakery markets.
Based in Whitefield, Manchester, this factory produces a diverse array of floured baps, brioche-style buns, and ready-to-roll pizza doughballs. Impressively, it manufactures over 1.2 million bread rolls daily, serving prominent national wholesalers and key sectors, including hospitality, healthcare, education, and the quick-service grab-and-go industry.
This investment initiative will unfold over the next 12 months. Currently, the first phase is in progress, focusing on enhancing product consistency and quality. A state-of-the-art robotic water splitter has already been implemented, designed to offer Kara an expanded array of designs and finishes for its rolls and loaves.
Additionally, significant asset upgrades are planned for the proofing and packing areas, which will streamline operations.
Looking ahead, phase two is set to commence in 2026. This phase aims to refine product presentation while optimizing quality and efficiency throughout the entire production process. A major upgrade to the pizza doughball production line is also on the agenda, responding to the rising demand for frozen dough balls in the quick-service sector. This enhancement will feature a new divider and line setup, anticipated to boost capacity significantly.
“This is a transformative time for Kara; we’re upgrading almost every part of our production process, from proofing and slicing to packing and wrapping, to improve quality, drive efficiency, and unlock innovation for our customers. From advanced robotics to new packaging lines, this investment is a major vote of confidence from Finsbury in the future of Kara and the wider foodservice market,” commented Suzanne Cooper, site operations manager at Kara.
Furthermore, the site will benefit from sustainability enhancements through energy efficiency improvements tied to these upgrades. Recent initiatives include the adoption of smart LED lighting, enhanced internal temperature controls to significantly reduce heat loss, and the rollout of a comprehensive energy management system.
Originally acquired by Finsbury in 2014 as part of the Fletchers Group of Bakeries, Kara stands as Finsbury’s sole site dedicated exclusively to foodservice.
