Case Study: Project Artemis – Delivering Hygienic Safety Infrastructure for AB Mauri, Northampton

Project Overview

  • Architect: Meller
  • Main Contractor: Clegg Construction
  • End User: AB Mauri
  • Project Name: Project Artemis
  • Location: Northampton
  • Sector: Food Industry - Manufacturing & Processing
  • Site Area: 1.396 hectares
  • New Floor Area: 373 sqm
  • Units: 1

AB Mauri’s Northampton facility is a major strategic site within their UK network. As part of a significant redevelopment programme, Clegg Construction was appointed as the main contractor to deliver a complex, multi-phase upgrade across both internal and external operational zones. Their remit included structural extensions, new plant areas, office refurbishments and upgraded logistics access.

Working as part of Clegg’s wider delivery team, Brandsafe was brought in to design and install a suite of hygienic impact protection systems to support the demanding requirements of a live food production environment.

Protecting People, Processes and Hygiene Standards in a Live Food Production Environment

When AB Mauri committed to expanding and refurbishing their Northampton site, the project demanded a coordinated approach between architect Meller, main contractor Clegg Construction, and specialist suppliers.

As the construction lead, Clegg Construction oversaw the sequencing of works across a live operational facility, managing tight access constraints, programme pressures and the need to maintain full hygiene compliance throughout the build.

Brandsafe was appointed to support Clegg’s delivery by supplying and installing high visibility, hygienic impact protection solutions across key operational zones. These systems played a vital part in ensuring the new infrastructure met food industry safety standards while protecting personnel, plant and processes during and after construction.

Site Challenges and Requirements

From the outset, the project faced several key challenges:

  1. High-Risk Movement Areas: The presence of HGV traffic, forklifts, and MHE vehicles operating near staff and sensitive production zones increased the risk of collisions.

  2. Strict Hygiene Compliance: All protection systems needed to support hygiene protocols. This meant seamless finishes, easy-clean surfaces, and corrosion-resistant materials.

  3. Spatial Constraints: The site layout included complex geometry between extensions and plant areas, requiring bespoke barrier configurations.

  4. Live Site Conditions: Construction was carried out in a live operational facility, necessitating careful coordination and minimal disruption to ongoing production.

The Brandsafe Safety Solution

To address these demands, Brandsafe specified and installed a range of products designed to deliver high-impact protection, long-term durability, and visual clarity. All items were installed in accordance with Brandsafe’s manufacturer guidelines and delivered to full hygiene specification.

1. Single Bumper Barriers

Installed throughout high-traffic pedestrian zones and internal walls, Brandsafe’s Single Bumper Barriers offer low-level protection with exceptional resilience. These barriers are constructed from high-density polyethylene (HDPE) in a safety yellow and grey finish, mounted on 300mm footplates for strong anchoring.

  • Height: 260mm
  • Lengths: 900mm upwards
  • Application: Delineating safe walkways, wall protection, internal segregation
  • Benefits: Flexible layout, easy-clean surfaces, impact resistance for internal environments

The choice of HDPE ensures high chemical resistance, ideal for areas where food-grade cleaning agents are used. The yellow finish enhances visibility, helping site operatives to clearly identify safe areas and obstacles.

2. Door Protection Goalposts

To protect new rapid roll doors (3m x 3m), Brandsafe supplied Goalpost Protection Systems comprising a combination of bollard base units and ImpactSAFE buffers.

  • Base: 210mm diameter bollard
  • Uprights & Crossbar: 89mm diameter steel with HDPE sleeves
  • Finish: Yellow and Black with reflective markers
  • Construction: Hot dip galvanised steel and polymer combination
  • Application: Protection for high-traffic doorways exposed to forklifts or HGVs

This system allows for safe vehicle passage while maintaining critical doorframe protection. The spigot joint design offers mechanical stability, while the HDPE sleeves provide excellent resistance to impact and wear.

Materials Overview – Project Artemis

As part of the wider redevelopment at AB Mauri’s Northampton facility, Clegg Construction led extensive upgrades across the site, covering improvements to traffic flow and drainage, refurbishment of welfare and operational spaces, enhanced access control, structural works to lobby and airlock areas, and new effluent treatment installations. These works were designed to meet modern food grade standards for efficiency, hygiene and long term resilience.

Within this construction framework, Brandsafe supplied and installed a tailored package of impact protection systems to support both operational safety and hygiene compliance.

Impact Protection Systems Installed

Single Bumper Barriers

High density polymer barriers installed along internal walls, walkways and production areas to deliver continuous low level protection. Their smooth, easy clean surfaces make them ideal for food manufacturing environments where hygiene is critical.

ImpactSAFE Bollards

Heavy duty bollards featuring galvanised steel cores with polymer sleeves, positioned at doorways, corners and vulnerable structural points to absorb impact and maintain safe traffic flow throughout the facility.

Goalpost Protection Systems

Robust protective frames installed around rapid roll doors and high traffic access points. The combination of steel and HDPE cladding provides strong structural defence and a hygienic, easy to maintain finish.

Integrated into the Construction Programme

Working in coordination with Clegg’s programme, Brandsafe’s systems were installed at key project stages to protect newly completed areas immediately and ensure long term operational durability. All products were selected for their resilience, hygiene compatibility and suitability for intensive use within a live food production environment.

Results and Benefits

The implementation of Brandsafe’s impact protection systems at AB Mauri’s Northampton facility delivered a wide range of tangible benefits, including enhanced safety and improved ease of cleaning. These align closely with the needs of a high-performing food manufacturing site. Designed with durability, visibility and hygiene in mind, the installed solutions have contributed to a safer, more efficient and future-ready operation.

Enhanced Safety Across Critical Zones

One of the most immediate outcomes of the project was a substantial increase in safety across the facility. High-risk areas, including HGV docking points, internal doorways and walkways, are now clearly protected with robust polymer and steel systems. These solutions significantly reduce the risk of damage caused by material handling equipment, forklifts and site traffic. By mitigating collision risks, Brandsafe’s products help prevent costly repairs, reduce downtime and enhance protection for both assets and personnel.

Improved Operational Visibility and Awareness

The use of high-contrast colour schemes, including Safety Yellow, Black and Grey, paired with diamond-grade reflective markings, provides strong visual guidance throughout the site. These visual cues support safe navigation, even during low-light or night-time operations. Clear delineation of pedestrian and vehicle routes enhances operational awareness and reduces the likelihood of avoidable incidents.

Designed for Hygiene and Regulatory Compliance

All impact protection systems were specified and installed with hygiene as a priority. Materials such as high density polyethylene (HDPE) and rubber are resistant to bacterial retention and to cleaning chemicals. Their low retention surfaces and minimal seams help prevent the build up of contaminants. Goalposts were sealed along the rubber buffer to improve ease of cleaning and prevent the accumulation of dirt. This supports ongoing compliance with food industry regulations, quality assurance procedures and third party audit requirements.

Long-Term Scalability and Maintenance Efficiency

Each system was selected for its modular construction, enabling easy replacement or reconfiguration as the site evolves. This adaptability ensures long-term cost efficiency and allows the client to respond to operational changes without extensive structural works or interruptions to production. In addition, maintenance requirements are minimal due to the durable, low-maintenance nature of the materials.

Sustainable and Durable Infrastructure

The materials used across the project are engineered for long term performance. Their resistance to corrosion, impact damage and general wear reduces the need for frequent replacements, contributing to improved sustainability and reduced operational waste. This supports AB Mauri’s longer term environmental and operational goals.

Operational Impact

The outcome of this installation is a cleaner, safer and more productive environment that meets the specific demands of modern industrial baking operations. With critical risk areas protected and hygiene protocols supported, AB Mauri can continue its production activities with confidence, knowing its facility is built for both present-day needs and future challenges.

Leadership Commentary on the Success of Project

"Working alongside Clegg on this project gave us an excellent opportunity to demonstrate the strength and versatility of our impact protection solutions, from our Single Bumper Barriers to our ImpactSAFE Bollards and Goalpost Protection Systems, each designed to perform reliably in a highly demanding food production environment. I am incredibly proud of our sales, operations and installation teams, whose hard work and professionalism ensured the project was delivered to an exceptional standard." George Howe - Head of Commercial Sales.

Project Outcomes

Project Artemis illustrates how considered planning and precise product specification can significantly enhance both the structure and safety of an industrial site. By working closely with Meller and the wider construction team, Brandsafe delivered a tailored impact protection solution that addressed the specific challenges of a live food manufacturing environment.

From protecting critical infrastructure to reducing risks to personnel, every element of the installation supported AB Mauri’s ambition to create a modern, efficient and compliant production facility.

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