Project Overview
- Client: Forza Doors
- Location: Partridge Green, West Sussex
- Facility Size: 130m² spray shop
- Completion: April 2024
- Scope: Design and installation of spray booths, drying room, and handling zones
Meeting the Challenge
When Forza Doors began a £3 million expansion to boost door manufacturing capacity, the company needed a spray shop facility capable of matching its increased output, without compromising quality or lead times.
Based in Partridge Green, West Sussex, Forza Doors is the UK’s leading manufacturer of bespoke timber fire doors and joinery. Their new 16,000 ft² factory has increased production capacity by 60%, supporting ongoing growth and maintaining industry-leading turnaround times.
To deliver a high-quality finishing facility on time and within budget, Forza turned to Elmbridge a trusted partner with proven experience in spray booth design and installation.
Collaborative Design Process
Elmbridge Project Manager, Bradley Hext, led the design and build of the 130m² spray shop area.
Initial 2D layouts maximised the available space, followed by a consultative design process with multiple site visits and review meetings. Once finalised, Elmbridge’s drawing office created full 3D CAD visuals and hosted a virtual walkthrough at their Gloucester HQ for sign-off.
“It was essential that Elmbridge not only met the design brief but also delivered within our agreed budget and timescales, aligning with our wider expansion project,” explains Colin Bicknell, Operations Director at Forza Doors.
With designs approved, manufacturing took ten weeks, followed by a four-week build and installation period.
Installation and Delivery
Deliveries to site began in mid-March 2024. The main mechanical installation was completed in three weeks, with additional time for ductwork, electrical systems, and gas connections.
“We worked closely with Forza’s team, from directors to production managers to keep everyone aligned and address any issues immediately,” says Bradley.
Efficient access to the new workspace helped prevent delays, and the installation ran to schedule throughout.
Design Innovations
Two key features made this project stand out:
- Flash-off Corridor: A dual-purpose entrance lobby creating a dust-free entry zone that also serves as a handling area for freshly painted components before drying.
- Bunded Pump Stations: Bespoke fabricated pump bases incorporating a compressed air system with breathing-quality filtration and integrated storage for blow guns.
The Finished Facility
The completed installation includes two fully enclosed spray booths with automatic self-balancing systems to eliminate airborne dust and maintain consistent performance.
Supporting Forza’s environmental goals, the setup features LED lighting, centrifugal fans, inverters, and IE4 premium-efficiency motors for reduced energy use and noise levels.
Operator training was provided across both shifts to ensure the teams were confident using the new equipment from day one.
“Elmbridge managed the entire project seamlessly, from design to installation,” Colin adds. “They coordinated with external suppliers and addressed challenges promptly, ensuring the project stayed on time and on budget.”
Results
Forza Doors’ new spray facility integrates smoothly into their expanded production line, improving efficiency and supporting continued growth. The collaboration with Elmbridge delivered a high-performance, future-ready solution, built around precision, practicality, and partnership.
Case study supplied by Elmbridge UK.
Elmbridge UK
Forza Doors
