Unilever’s largest food manufacturing facility, located in Burton, has recently undergone a remarkable transformation with an investment of £40 million, aiming to consolidate its condiments business into a single operational hub.
Notably, 99% of the products produced at Unilever’s Burton site are distributed exclusively to UK retailers. This substantial investment is poised to bolster the ongoing expansion of Unilever’s food business within the UK. The primary focus of this initiative is to enhance supply chain efficiencies, elevate production capabilities, and achieve significant production growth at the facility.
As a part of this transformation, Unilever has constructed an additional factory adjacent to the existing one. This expansion has resulted in a 50% increase in the site’s footprint, now covering 31,000 sqm of operational space. The new facility will facilitate the production of popular brands such as Hellmann’s, Marmite, Bovril, and Colman’s—all of which will be produced under one roof.
The investment has also included the enhancement of digital capabilities, establishing a “highly optimised” production environment across two food factories and nine production lines. Impressively, this transformation has enabled the site to double its production volume while achieving a 13% increase in overall factory efficiency over the past three years. With the completion of the final investment phase in 2023, which includes the introduction of a new production line specifically for Hellmann’s products, 2024 is anticipated to be a record-breaking year for the factory. The site is expected to produce an average of 9 million jars and bottles of condiments each month.
This strategic investment and subsequent growth have resulted in the creation of 160 new jobs at the factory. In addition, Unilever is committed to empowering its existing workforce by providing opportunities for the current employees to develop new skills in digital manufacturing. This investment builds on the site’s rich 100-year history of supporting local employment and skills development.
Andre Burger, Unilever UK & Ireland Foods Lead, remarked, “The investment in our Burton site and new factory reaffirms the site as a key food hub for British produce, making delicious condiments that are helping to create meals in homes up and down the country every day.”
He further emphasized, “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.”
Additionally, Burger articulated, “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.”
Environmental Impact: CO2 Savings from Investment
In tandem with enhancing productivity, Unilever has ensured that this investment also contributes to a significant reduction in the environmental footprint of the site. The focus remains on minimizing food waste and lowering the carbon footprint of its products. Notably, the increased adoption of real-time data analysis has facilitated a remarkable halving of food waste at the facility since 2021. The remaining food waste is efficiently redistributed—either transformed into energy for the factory via the on-site biogas recycling system or repurposed as feed for local farm animals.
Furthermore, the final-stage production of Hellmann’s 100% recycled plastic squeezy bottles has now been incorporated into the Burton facility. This stage involves inflating the basic recycled plastic material into the distinctive full-sized shape of Hellmann’s squeezy bottle. By localizing these key aspects of Hellmann’s production and packaging, Unilever has significantly decreased the number of lorries on the road, thereby reducing travel time from production to retail shelves. This localizing strategy has not only streamlined operations but also resulted in measurable CO2 savings, demonstrating Unilever’s commitment to sustainability.
