Planning the future shape of operations

Masterplans are good for any business. They become essential when considering operational change that impacts the physical environment.

Change could be sponsored by any number of factors. In our recent experience, Lorien has led Masterplans based on the following drivers:

  • Capacity versus demand
  • Efficient operation: COGS reduction
  • Manufacturing network re-alignment to market requirements
  • New products launch or acquisition
  • Replacement of key assets
  • Supply chain / distribution chain change
  • Quality and regulatory impact
  • Safety, security and environment ​​​​​​

Project drivers, direction, overall concept, boundaries and schedule requirement.
Consider areas and operations impacted.

Site Physical Masterplan and Architectural

Process and Process Utilities

Filling and Packaging

Control and Automation


Agree Concept Design Strategy options

Client & Lorien Review; agree final option(s) for reporting

Master Plan Output Report (with Cost Plan, Time Plan, Options analysis)

The only thing that is constant is change.

Heraclitus of Ephesus, 500 BC

Considering the approach and the objective

Our technical and project specialists work with your team to assess the technical and financial viability of investment options.

  • Masterplanning for individual locations
  • Strategic masterplans concerning networked operations
  • Operational review and de-bottlenecking
  • Concept design
  • Scheme design

There are some commonly sought objectives to be considered in a manufacturing or logistics concept design:

Safety & Security

  • Material and people flow analysis and optimisation
  • Eliminate crossing flows
  • Access for maintenance
  • Security control for vulnerable areas, functions, product
  • Product safety & regulatory

Efficient Operation

  • Logical flow
  • Automation vs. people review
  • Eliminate bottlenecks
  • Logistics strategy
  • Occupation density (and safety)
  • Warehouse / transport / despatch interfaces


  • Establish cleanliness regimes
  • Devise zoning: segregation vs. functionality
  • Constraints associated with existing building configuration
  • Product handling systems
  • Optimal process automation

Capacity versus Demand

  • Understanding key capacity drivers for development
  • Daily and seasonal demand profiles
  • Inbound & Outbound product routing review and optimisation
  • Vehicle access and driver accommodation
  • Features allowing expansion

Capability of turning a masterplan into reality.

We have a solid track record in undertaking Masterplanning, including as examples:

  • Brewing
  • Soft drinks
  • Food ingredients
  • Ready meals and convenience foods
  • Pharmacy products
  • Aerospace
  • Occupational safety products
  • Building products
  • Confectionery
  • Baked products
  • Pharmaceutical and well-being

Confidential and unbiased executive reporting

Our confidential unbiased executive output reports provides you with an independent view of the proposed options, examining the opportunity for change, with outline costs and time scale based upon our experience of delivering over £20bn of CapEx change projects.



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Partner with us

In partnering with Lorien you will find people who understand engineering design, and who can guide your projects from concept design through to an operational, commissioned and validated state.  Investment projects can often come with challenges, such as construction and installation to occur alongside live plants; time and cost constraints; construction in challenging environments. 

Whatever the challenge may be, with over £3bn of constructed projects behind us, you can be assured that the team at Lorien is very likely to have met similar challenges and managed through to an effective outcome.

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