The Paradise Street facility in Basildon, Essex, is Europe’s biggest coffee roastery and covers 85,690 sq ft – the equivalent of more than 30 tennis courts – and will produce enough coffee for 2.1 billion cups a year.
Costa said that the building had been carefully designed to improve efficiency.
Green coffee beans from Rainforest Alliance1 certified growers are shipped to Tilbury Docks 14 miles from the roastery – half the distance to Costa’s old Lambeth roastery, meaning fewer road miles and much improved supply chain efficiency.
Once the beans arrive, new production methods allow the receipt and storage of 24 tonnes of green coffee per hour – up from 6 tonnes at Lambeth. Whilst roasting the coffee, state-of-the-art in-house processes increase productivity by 25 per cent compared with the previous roastery.
The frame of the building is zero energy and the site operates on a zero waste-to-landfill basis.
On-site renewable energy generation will further reduce the building’s carbon footprint, with the roof hosting a 249kw solar PV system which will provide power for the roastery. In tandem with a rainwater harvesting system, this will also generate hot water for the building.
Dominic Paul, managing director of Costa, said: “Costa is growing rapidly as a global business and our new roastery will provide the platform for sustained international expansion as we continue inspiring the world to love great coffee. Turning on our new roasting capacity is a landmark for the business. It’s a statement of our ambition to grow and our passion for great coffee.”
“Roasting here in Basildon keeps the UK at the centre of our growing global brand and enables us to build on everything we have learned from more than four decades of roasting in Lambeth. Today is about quality, capacity, investing in the future and being true to our heritage – it’s about embracing our traditions whilst continuing to innovate and drive global growth.”