When Forza Doors began a £3m factory expansion at its Partridge Green site in West Sussex, the finishing operation was identified early as critical to the project’s success. Increasing output without compromising quality or lead times required a purpose-built spray facility designed around real production demands.
From the outset, Forza worked closely with Elmbridge to plan and deliver a spray shop that would integrate into the wider expansion. Elmbridge took responsibility for the full design and installation of the 130m² spray facility.
Planning a finishing facility for increased capacity
The expansion has seen Forza’s new 16,000 ft² factory increase production capacity by 60 percent, supporting continued growth in its bespoke timber fire door and joinery operations. Central to this uplift is a finishing setup designed to support throughput, consistency and long-term scalability.
Elmbridge Project Manager Bradley Hext led the design and build process, beginning with 2D layouts to maximise the available footprint. A consultative design phase followed, supported by site visits and review meetings. Once agreed, Elmbridge produced full 3D CAD visuals and hosted a virtual walkthrough at its Gloucester headquarters to support final sign-off.
“It was essential that Elmbridge delivered within our agreed budget and timescales, aligning with our wider expansion project,” explains Colin Bicknell, Operations Director at Forza Doors.
Design, manufacture and installation
Manufacture of the spray shop equipment took ten weeks, followed by a four-week installation programme. The main mechanical installation was completed within three weeks, and the ducting, electrical systems and gas connections were coordinated alongside other works to maintain progress on site.
Two design features were central to the final layout. A dual-purpose flash-off corridor provides a dust-controlled entry zone while also acting as a handling area for freshly painted components. Bespoke bunded pump stations integrate compressed air systems with breathingquality filtration and built-in storage for blow guns.
A facility built for performance and consistency
The completed facility includes two fully enclosed spray booths with automatic self-balancing airflow systems to maintain consistent performance and reduce airborne dust. Energy-efficient LED lighting, centrifugal fans, inverters and premium-efficiency motors support reduced energy use and lower noise levels.
Operator training was delivered across both shifts, ensuring the spray shop was operational from day one.
The spray facility now operates as a fully integrated part of Forza Doors’ expanded production line, delivering a practical, future-ready finishing solution built through close collaboration.
