BSB Engineering has taken another step forward with the relocation to its new 80,000-square-foot facility in Aylesford. This strategic move marks a significant milestone, driving greater efficiency, production capacity, and employee well- being—all while reinforcing BSB’s position as a market leader in the manufacture and supply of Fire, Smoke and Air Control dampers and ventilation solutions.

With its previous Sittingbourne facility at full capacity, the transition to Aylesford was a long-term project one that, at times, seemed almost impossible. Reflecting on the journey, Richard Harber, Head of Operations & Systems, explained:

“It was a long planning project, and at one point, it seemed like an impossible task. But now that we are here, the improvements in efficiency are undeniable.”

The previous factory layout created inefficiencies due to frequent movement between workstations. The new site has been strategically designed to streamline production, significantly reducing unnecessary motion, and boosting overall workflow.

“Initially, it didn’t seem as busy, but that’s because people aren’t moving around as much. Now, they’re stationed where they need to be, and overall efficiency has increased.”

The Aylesford facility has allowed BSB to invest in state-of-the-art technology to support large-scale projects on a global scale.

The site now features:

• CNC laser and advanced punching machines for precision manufacturing.
• A dedicated heavy-duty production area to accommodate project specific custom built orders.
• High-capacity cantilever racking system to maximise storage space for raw materials, ensuring faster turnaround times for clients.
• An in-house testing facility to maintain strict air leakage and performance testing standards.

This investment has resulted in a significant increase in efficiency, according to Matthew Harris – Production Manager.

“We now have the space to optimise our workflows, meaning we can fulfil customer orders faster while maintaining the highest quality standards, ensuring even more growth potential.”

Impressively, the FD-C line alone produces over 300 units per day.

One of the biggest transformations at the new facility is the integration of automation. BSB is investing in robotic welding, automated material handling, and coil-fed machines that streamline production and enhance precision.

“We are in the early stages of implementing robotics, but automation is a key focus. We’re looking at introducing machines that will make processes more efficient,” Richard explained.

This investment not only improves productivity but also reinforces BSB’s commitment to innovation in precision engineering.

Positioned in the heart of the Southeast’s transport network, Aylesford offers seamless links to London and beyond, providing a strategic advantage in logistics.

“London remains the focal point for major construction projects, and being based in Aylesford gives us a strategic edge,” explained Jack Sturrock-Leaton, Regional Sales Manager for the Southeast. “Our ability to quickly build & supply M&E contractors, distributors, and wholesalers with stock is crucial. Speed and reliability are everything in this industry.”

This prime location allows BSB to enhance nationwide distribution, ensuring faster delivery across the UK critical for supporting major infrastructure projects, hospitals, and high-rise developments.

“We spend a lot on couriers and deliveries, so we’re assessing whether to expand our own transport fleet to improve cost efficiency,” Richard Harber added.

Beyond production improvements, the move has had a transformational impact on BSB’s workforce. With 140 employees, some with over 30 years of service, the company prides itself on staff retention and internal growth.

“We’ve seen a real boost in morale,” said Nygel Humphrey – Commercial Director. “The new facility is modern, spacious, and well-equipped. It’s not just about production—it’s about providing a fresh working environment that supports our growth, that our employees are proud to be part of.”

BSB is also committed to ongoing training and development, ensuring staff can advance within the company.

“We have a structured management training program, covering first-line management, specialist safety training, and cross-department collaboration,” Richard Harber explained.

BSB’s move to Aylesford is not just about meeting current demand—it’s about future-proofing the company. The additional space allows for:

• The introduction of new product lines.
• Enhanced distribution networks to support larger projects.
• A new training facility for accredited CPD programs.

“We’re constantly evolving,” said Jack Sturrock-Leaton. “Our goal is to provide the best solutions in fire and smoke control, and this move has positioned us perfectly for future growth.”