DoorCo is widely recognised for its focus on product innovation and continuous development, and that same forward-thinking approach extends to its internal processes and operational structure. The full integration of the company’s Thorne facility in Doncaster marks a significant milestone in its long-term strategy, strengthening manufacturing capability, logistics resilience and future innovation.

Acquired in 2023, the 3.2-acre Thorne site provides DoorCo with an additional 80,000 sq.ft of space to support its manufacturing headquarters in Macclesfield. Since the acquisition, the business has been working towards creating a dedicated hub for manufacturing, storage and innovation, plans that are now coming to fruition as the site enters full operational use ahead of 2026.

The first phase of redevelopment focused on manufacturing, with Doncaster becoming the home of BRiTDOR, DoorCo’s solid timber-core door range available in 44mm and 48mm options. Designed to support the company’s ambition to become a single, comprehensive supplier of entrance doors, this area occupies approximately 25,000 sq.ft and has benefited from more than £1 million of investment over the past 20 months in building upgrades and specialist machinery.

This was followed by the installation of an automated high-volume staining line, introduced to deliver more consistent colour matching across DoorCo’s door designs, including FLiP glazing cassettes. The system also improves colour alignment between FLiP cassettes and the BRiTDOR range, enhancing overall product consistency.

Further investment targeted FLiP foaming capacity, enabling DoorCo to scale production significantly. With more than 750,000 FLiP cassettes sold this year, the system has strengthened its position as the market-leading door glazing cassette solution. The scale of the Doncaster site has allowed increased pre-foaming space and the introduction of a second production shift to meet growing demand.