Client & Project Overview
Dew Valley Foods is a well-established cooked bacon manufacturer.
They have a strong commitment to ethical production, sustainability, and long-term business growth. In preparation for a significant increase in demand, Dew Valley embarked on an ambitious expansion strategy aimed at increasing production capacity by 80 per cent over a ten-year period. Alongside this growth, the company sought to improve operational efficiency, reduce energy and resource consumption, and embed sustainability across its manufacturing operations.
PEMCAS was engaged to support this expansion through detailed assessment, planning, and engineering design. Following close consultation with the client and a comprehensive review of the existing facility, PEMCAS recommended a phased delivery approach comprising two key projects: a substantial expansion of the manufacturing facility and the development of a dedicated customer visitor centre. This dual strategy supported both production growth and enhanced engagement with customers and stakeholders.
Advanced 3D modelling was used to analyse the existing factory layout and proposed expansion, allowing opportunities for operational efficiency to be identified early. These models supported informed decision-making, improved coordination across disciplines, and reduced disruption to ongoing production. PEMCAS also managed the full compliance and regulatory approval process, securing all required permits and licences—an extensive undertaking given the scale and regulatory complexity of large-scale food manufacturing projects.
The completed expansion and visitor centre have proven to be a commercial success for Dew Valley, delivering increased capacity, improved operational performance, and meaningful reductions in water consumption, kerosene usage, and waste to landfill, while supporting local employment growth.
Key Insights
Delivering complex projects in the food production sector requires a careful balance between commercial ambition, regulatory compliance, and sustainability. Early analysis and detailed modelling enabled efficiency improvements to be embedded into both the expansion and the existing facility, generating long-term operational and environmental benefits.
Dew Valley’s commitment to growing their business in a responsible and ethical way aligned strongly with PEMCAS’s value-driven approach to engineering design and delivery. By working closely with the client throughout planning, compliance, and construction, PEMCAS demonstrated the technical competence, performance, and reliability that underpin trusted long-term partnerships. This project highlights how strategic engineering support can enable sustainable growth while reinforcing brand values and operational resilience.
