Arla Foods
- Sector
- Manufacturing
- Location
- Aylesbury
- Year
- 2013
- Client
- Arla Foods (UK) Ltd
- Architect
- DLA Architecture
- Structural Engineer
- JPG Holdings Ltd
- Quantity Surveyor
- Richard Boothroyd & Associates
- Principal Designer
- Jacobs Feasey Associates
- Value
- £87.8m
Caddick Construction delivered a 720,920 sq ft flagship dairy facility for Arla Foods in Aylesbury - one of the most sustainable milk processing plants in the world.
Designed to set new benchmarks for efficiency and environmental performance, the project achieved a BREEAM Excellent rating.
Overview
The development included a 624,080 sq ft main dairy building with high-performance cladding and extensive prefabricated M&E installations to accelerate delivery. Supporting facilities included a 37,660 sq ft office building, a 53,800 sq ft energy centre, and a 5,380 sq ft transport office, alongside vehicle wash stations, fuel areas, and gatehouses. The scheme combines innovation, scale, and sustainability to support Arla’s long-term growth and low-carbon operations.
Challenges
Delivering one of the UK’s largest food processing facilities demanded complex coordination and precision. Caddick’s use of prefabrication reduced build time and enhanced quality, while strict environmental and hygiene standards were maintained throughout. Working within live infrastructure networks required careful planning to manage heavy logistics, minimise disruption, and ensure continuous operational readiness.
Social Value
Caddick worked closely with local residents and businesses, maintaining regular communication throughout construction. Community benefits included student site visits, college presentations, and a partnership with HM Prison Aylesbury providing rehabilitation employment opportunities.
The project supported local charities, improved access roads for the 9th Aylesbury group, and raised funds for The Pepper Foundation. The scheme generated a Social Return on Investment of £21.2 million and achieved a CCS score of 40, reflecting Caddick’s commitment to positive local and social impact.
Sustainability
Sustainability guided every aspect of the design and delivery. The facility achieved zero waste to landfill, with an anaerobic digestion unit processing up to 500,000 litres of waste daily to generate renewable energy. A combined heat and power (CHP) system produces 4 MW of electricity and 4.2 MW of heat, with 11% of its gas sourced from on-site digestion. Energy efficiency measures include heat recovery systems, rainwater harvesting, and intelligent building orientation to reduce solar gain.
The 34-acre landscaped site features extensive woodland planting, biodiversity corridors, PV panels, EV charging points, and sustainably sourced materials - establishing Arla Aylesbury as a global model for low-carbon food manufacturing.
