While other leading names are busy getting out of offsite manufacturing, British Offsite is about to move into a new £45m factory to manufacture up to 4,000 new homes a year.
The new 137,000 sq ft factory, on the Horizon Business Park in Braintree, Essex, has been designed in collaboration with Swedish robotic engineering firm Randek, which uses automated manufacturing to produce a light-gauge steel panel system and other components used for the onsite delivery of the superstructure and internal fit out of houses, multi-rise and high-rise developments.
The new factory is expected to serve both Weston Homes – the group's volume housebuilding division – as well as third-party contractors and developers including local and regional house-builders.
The Horizon factory will manufacture British Offsite's UniSystem, comprising light-gauge panels, walls, roofs and floors. The UniSystem panels are produced complete with windows, doors, insulation, vents, fire stopping and external cladding manufactured to the customer's specification. The UniSystem is a 'hybrid MMC' (modern method of construction) that is designed to be flexible and allow rapid integration into traditional building design.
British Offsite also manufactures internal fit-out modules under the BOS Fitout brand. This includes bathroom components, kitchen and bedroom products, designed to be easily integrated into existing projects, with full quality control testing before elements reach site.
The initial design concepts and commissioning of technology for the factory started three years ago, with the actual construction of the building taking 12 months. The automated production line, inspired by the automotive industry and designed by Randek, represents £5.3m of capital expenditure and is based around eight robots, designed and supplied by Randek.
British Offsite is the first Randek customer in the UK to receive the new machinery, automation and productivity solutions. The robots work together in three teams to control a series of zero-labour production cells including fitting insulation panels, fitting plasterboard panels and cutting window openings.
According to British Offsite, the production line is not limited to house-building and has the capacity to produce modular school buildings, healthcare facilities and student accommodation as well.
Once the factory is fully operational it will run a two-shift system five days a week. British Offsite plans to employ around 180 people on the factory floor and offices over the two shifts.
