Cǒtes Production Unit

Completed in 2022, this project involved the fit out of an existing DHL warehouse in Heathrow to create a centralised cooking and distribution centre for Cote Foods Group.

Appointed from RIBA Stage 1 under a design and build contract, the works included a full fit out of the shell to create a single storey facility with large void space above for ventilation plant, accessed via a new mezzanine walkway level, which also led to the two-storey office and welfare areas at either end of the new facility.

We subdivided the space and used hygienic wall coverings throughout, to create new production facilities, warehousing, new commercial kitchens, blast chillers, cold store areas, dock levellers and new distribution equipment installations.

The M&E, equating to almost half the project value, was replaced with all new including sprinkler systems, lighting, ventilation and dock levellers.

Early involvement from RIBA Stage 1 enabled close collaboration and regular workshops with the client and design team – maintaining critical alignment between design, cost, and programme.

We introduced modular hygienic wall systems and prefabricated service components, reducing installation time while improving quality. Our design input also helped futureproof the facility for potential operational expansion, providing long-term value to the client.

Works were carefully sequenced to accommodate complex M&E installation and commissioning. Early involvement enabled efficient planning and early procurement of long-lead items, minimising programme risk. Client-driven design changes were managed through structured change control and coordination workshops, with the project completing on time and within agreed budget.

All subcontractors were procured from our approved supply chain and engaged early to contribute technical input during design development. Trade packages were clearly defined through detailed scopes and coordinated interface workshops. Our site management team provided daily supervision, while our Quality Manager implemented inspection and test procedures to ensure compliance with food production and hygiene standards.

We provided comprehensive operational support, including attendance during commissioning and early operational testing. Our aftercare team remained on call to resolve any technical queries and ensure systems performed as intended. Post-completion, we returned to site to carry out seasonal balancing at strategic points and provided a full aftercare service with service level agreements agreed prior to practical completion.