Designing a future-proof insect protein facility
Overview
Willett Food Projects (WFP) were engaged to provide a peer-level review of an existing development proposal for a new insect protein facility. The aim was to work collaboratively with the existing design team to develop a robust construction budget and programme for the project.
Project objectives
The budget scope covered all costs outside of the specialist OEM (original equipment manufacturer) scope typically associated with a facility of this nature.
The primary objective was to support the installation of a new insect protein facility with modular expansion capability to meet both day-one and year-five feedstock input capacities. The project was set within a ~120,000 ft² warehouse.
Project delivery
The project scope covered extensive civil, structural and MEP works, including below-ground drainage, mezzanine construction, plant gantries, secondary steelwork, HVAC penetrations and air-handling systems, full electrical and mechanical installations, industrial flooring, tank bunding, and structural modifications to support specialist process equipment.
Client
Large insect protein production facility
Facility size
120,000 ft² warehouse
Key delivery features
A comprehensive programme was produced, covering the full timeline from instruction to proceed through to commissioning. This included the landlord construction phase, OEM equipment lead times, fit-out contractor tendering and contracts, as well as the detailed design stage.
Indicative design options were developed, including facility layout plans, floor plans, and 3D visualisations.
Project results
Insect protein provides a sustainable and locally produced alternative to imported and often unsustainably harvested protein supplements, such as soy for agricultural feeds. Additionally, waste streams from the production process can be repurposed as high-quality fertilisers.
The projected carbon savings from diverting feedstock away from traditional waste streams (anaerobic digestion and landfill), along with the use of renewable energy and a process plant that replaces synthetic fertilisers, amount to an estimated reduction of ~1.3 tonnes of CO₂ per tonne of feedstock – equating to approximately 40,000 tonnes of direct CO₂ savings per year.
Conclusion
The project represents a significant step toward more sustainable and locally-driven food and agricultural systems. Willett Food Projects successfully supported the client by delivering a comprehensive review and planning package, contributing to a robust framework for facility implementation. The project stands as a strong example of innovative thinking in industrial facility design.
Work with Willett
Need a feasibility study for your food business? Looking for a new food factory design? We can cover every aspect of your project. Our multidisciplinary team and network of specialist contractors work together to deliver turnkey services for food manufacturers. So, you'll be supported every step of the way.
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Posted by Kirsty Willett on January 2nd 2026
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