Maelor Foods - Poultry Processing Facility
The Challenge
Maelor Foods set out to create one of the most advanced poultry processing facilities in the UK. The chosen site—a former dairy factory—required a complete transformation and significant expansion to meet the demands of modern food production. The goal was to deliver a high-capacity, efficient, and hygienic environment that adhered to strict industry standards.
Our Solution
RCA leveraged its deep expertise in food factory construction to design and build a state-of-the-art facility. The project included:
Specialised Zones: Side offloading area, holding area, gas pit, and bird preparation zones, including a dedicated fillet section.
Cold Store Infrastructure: Multiple chill rooms and loading docks to maintain product integrity.
Logistics Support: A purpose-built lorry park for streamlined transportation.
Sustainability Measures: Installation of a water treatment plant to ensure efficient and environmentally responsible operations.
The Result
The completed facility stands as the UK’s second-largest poultry processing plant, combining cutting-edge technology with operational efficiency. Mealor Foods now benefits from a modern, scalable infrastructure that supports high-volume production while meeting stringent quality and safety standards.
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Maelor Foods
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Wrexham, North Wales
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Industrial / Food Production
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2016 - 2019