From our smart facility layout embracing flow and lean principles to advanced automated production lines and a recent robotic introducion, our goal is simple: to deliver exceptional food, safely and sustainably at scale.
Over the past ten years, we’ve transformed The Lewis Pie Co. into a modern food production facility with a sharp focus on operational efficiency. Our U-shaped site layout enables unbaked frozen and baked fresh/frozen goods to move independently through clearly defined zones. This setup helps us to:
✔ Exclude product crossovers & contamination
✔ Optimise labour and line efficiency
✔ Improve hygiene, speed, and safety
✔ Reduce non value added roles
“Every part of my production hall has been designed with output and efficiency in mind, our team have made changes iteratively to improve things bit by bit. The flow makes our job faster, cleaner, and safer, and means we can compete and keep prices competitive – we all enjoy seeing the changes, the place has a great energy.”
— Mark Davies, Head of Pasties and Rolls
Automation That Adds Real Value
Automation at The Lewis Pie Co. is more than machines — it’s about unlocking quality, consistency, and scale without compromising our craft. We’ve partnered with world-class equipment suppliers from the UK, Switzerland, and Germany to upgrade our lines with intelligent pastry machinery, robotic handling, and automated glazing and panning systems.
This smart tech allows us to:
✔ Eliminate repetitive manual tasks
✔ Reduce physical strain for staff
✔ Increase precision, yield, and speed
✔ Keep a close eye on efficiency via real-time performance dashboards
We don’t use automation to cut corners, we use it to raise the bar.
“Automation here doesn’t replace people — it assists them. We’ve got the tools to keep getting better. I have been a direct part of that and to be honest that feels great. We are proud of what we do.”
— Anthony Thomas, Head of Pies
Refrigeration, Energy & Sustainability
Behind every great frozen product is a power hungry fridge or freezer system. At The Lewis Pie Co, we’ve made long-term investments in our chilling and freezing infrastructure. This is a part of our ongoing investment plan that not only protect product integrity but also reduce our environmental impact. Our Solar array is a direct offset to the refrigeration. When the sun shines hard fridges use more energy, luckily we produce more solar power.
Our site features:
- Modern Chilling and blast equipment
- Digital online Temperature monitoring
- Fully scheduled PPM (Planned Preventative Maintenance) for minimal downtime
- Future-ready upgrades, including waste heat recovery systems to generate hot water from refrigeration exhaust
We believe energy efficiency isn’t just good for the planet — it’s vital for the future of responsible food manufacturing.
Built for People, Powered by People
At The Lewis Pie Co, we know that a great facility means nothing without a great team. That’s why we’ve made serious investment in our work environment and staff culture, creating a place where our people feel safe, valued, and able to contribute every day.
We’ve built:
- Ergonomic, clean working spaces
- An environment where wellbeing is key
- A culture that brings us together — including monthly all-staff meetups with shared meals
It’s not just about operations. It’s about building a team that can take pride in what we make — and how we make it.
“What I like most is how hands-on we all get to be — everyone’s ideas are heard, and the tools we need are here. We get our heads together around the CI board and make things happen.”
— Andrew Perrons, Head of Pastry
Safety, Traceability & Compliance
Food safety is more than a requirement , it’s a non-negotiable part of who we are. Every area of our production facility is governed by strict quality control, allergen management, and traceability systems. We work to the standards of our BRCGS AA certification not just for audit day, but every day.
Our safety and compliance framework includes:
- Full digital batch tracking from raw material to finished product
- Managing critical control points
- Line-specific allergen controls and cleaning protocols
- Staff training and routine reviews to ensure standards are always met
These layers of control allow us to protect our product, your brand, your customer, and our shared reputation — with full transparency.
Summary of Facility Capabilities:
✔ U-shaped layout for product flow
✔ Fully automated pastry lines
✔ BRCGS AA certified environment
✔ Modern freezer & blast chill systems
✔ In-house software for real-time tracking
✔ Waste heat energy recovery (planned)
✔ Staff development kitchen & breakout areas
✔ Continuous investment in sustainability
📍 Want to See Our Site?
Whether you’re a wholesaler, foodservice provider, or looking for a long-term private label pastry manufacturer, we’d love
to show you what we do.
