Choosing the Right Site for a Food Manufacturing Facility: Retrofit or New Build? 

For food manufacturers planning a new facility, one of the most critical decisions you’ll face is site selection. Whether you’re considering a retrofit of an existing warehouse, the conversion of a shell building, or a ground-up new build on a greenfield site, the location you choose will shape the entire future of your project—operationally, financially, and environmentally. 

In today’s landscape, this decision is becoming more complex than ever, particularly as utility infrastructure struggles to keep pace with industrial growth. Here’s what you need to consider when selecting the ideal site for your next food production facility. 

1. Start With Strategic Location Planning

The age-old property mantra “location, location, location” still holds true—perhaps more so in the food manufacturing sector than most. 

Ask yourself:

• Will staff, suppliers, and logistics partners have easy access?
• How close is the site to your supply chain and customers? 
• Is the site well-connected to key transport routes? 
• Are there any major earthworks or topographical challenges that could increase build costs? 
• Are planning permissions and zoning regulations aligned with food production uses? 

These are fundamental questions. A remote site with poor infrastructure or excessive ground remediation requirements can add significant cost and delay to your programme. Meanwhile, a well-situated site with streamlined access to major roads or ports can bring operational advantages that pay back year after year. 

2. Don’t Underestimate Utility Constraints 

Utilities are now one of the most significant limiting factors when choosing a site for food production. The growing demand for electricity—driven by refrigeration, automation, and increasingly electrified processes—makes it essential to assess your power needs early on. 

You’ll need to evaluate: 

• Power capacity: Is there enough electrical load available to meet your current and future needs? 
• Gas availability: Is a gas main present, and does it support your cooking or processing operations? 
• Water supply and pressure: Are potable and process water lines available and sufficient? 
• Wastewater disposal: Does the site have the capacity to manage effluent in compliance with environmental regulations? 

Retrofitting an existing site may offer time savings in theory—but many older buildings are severely limited by their original utility connections. If you’re not careful, you may end up spending more on infrastructure upgrades than you would on a greenfield new build. 

A thorough utility audit should be conducted as part of your early feasibility work, ensuring that any limitations are known—and factored into cost and timeline planning—from the outset. 

3. Understand the Environmental Impact 

Every site has a footprint—not just physically, but environmentally. Whether you’re building from scratch or upgrading an existing structure, it’s important to assess: 

• Carbon footprint potential: Does the site lend itself to incorporating renewable energy or low-carbon building design? 
• Surrounding industrial activity: Are there any neighbours whose emissions, noise, or operations could impact food safety or compliance? 
• Wastewater and trade effluent: How is water treated, and are existing systems sufficient? 
• Environmental protections: Is the site near sensitive land, protected habitats, or in a flood risk zone? 

Sites requiring environmental impact assessments (EIA) can introduce significant delays and cost, especially if mitigation measures must be implemented. However, sites offering opportunities for energy-efficient upgrades or solar power can offer long-term savings and help meet your ESG objectives. 

4. Consider the Workforce 

Automation may be increasing, but people still play a vital role in food manufacturing. From machine operators and hygiene teams to engineers and quality control specialists, your site must attract and retain the talent you need. 

Key factors include: 

• Availability of skilled and semi-skilled labour 
• Local employment levels and wage expectations 
• Commutability and transport options 
• Access to training providers or partnerships with local colleges
• A labour market analysis will help you understand whether the location is viable for recruiting staff—not just today, but for future growth. 

5. Look Into Local and Government Incentives 

In some regions, particularly areas prioritised for regeneration or economic development, local authorities may offer financial or planning-related incentives to attract inward investment. 

These could include: 

• Capital grants for plant and equipment 
• Training and workforce development subsidies 
• Fast-tracked planning approval processes 
• Business rate reductions or tax relief 

Engaging with local enterprise partnerships (LEPs) or development agencies early can uncover opportunities to reduce your capital outlay or timeline. 

6. Navigate Planning Policy and Red Tape 

From food safety to fire regulations, the food industry is one of the most heavily regulated construction sectors. Layer on planning law, and things can get complicated quickly. 

It’s critical to: 

• Understand zoning permissions and permitted uses 
• Check for restrictions such as listed building status, conservation areas, or green belt protections 
• Assess flood risk, access rights, and easements 

Greenfield sites often offer a blank canvas but can trigger lengthy planning processes. Conversely, brownfield or industrial plots may already have B2 (General Industrial) or B8 (Storage & Distribution) classifications in place—yet be constrained by poor access or outdated legacy structures. 

A well-scoped planning appraisal will highlight potential red flags and identify paths to approval before you commit to a site. 

7. Choose the Right Type of Build: New or Retrofit? 

There’s no one-size-fits-all solution. Choosing between a retrofit of an existing building or a new build on undeveloped land depends on several factors: 

Retrofitting / Shell Fit-Out considerations 

• Faster planning, potentially lower upfront costs, may already be zoned for industrial use 
• Utility constraints, structural limitations, legacy design that doesn’t suit hygienic zoning or process flow 

New Build / Greenfield Development considerations 

• Purpose-designed layout, utility planning from the ground up, better opportunity for future-proofing and energy efficiency 
• Longer programme, potentially higher initial costs, greater planning and permitting complexity 

Each option carries trade-offs. A detailed Discovery —covering utilities, process fit, structural capacity, costs, and compliance—will ensure your decision is driven by long-term performance and savings, not short-term savings. 

Conclusion: Discovery First, Always 

There is no perfect site. Every option will come with compromises—whether cost, programme, complexity, or constraints. What matters is how well these are understood, prioritised, and managed. 

At DDK, our Discovery phase is designed to help you answer the big questions before committing to capital spend. We assess your operational needs, infrastructure requirements, site constraints, and compliance landscape—helping you make confident decisions that avoid costly surprises later. 

Whether you’re wanting to understand your options, exploring a retrofit or starting from scratch, smart site selection sets the foundation for long-term success. 

Ready to find your next site? Let’s get started. Contact us