+44 (0) 1895 268288

Brunel University of London
Uxbridge, Middlesex, UB8 3PH

parkroyal@brunel.ac.uk

 +44 (0) 1895 268288

Brunel University of London
Uxbridge, Middlesex, UB8 3PH

parkroyal@brunel.ac.uk

Case Studies

Our case studies offer a detailed insight into the way complex issues of food supply are resolved within a given context

Insights and latest developments on the Park Royal Industrial Estate by Prof Geoff Rodgers, Brunel University of London

Food and drink is the second largest manufacturing sector in the West London economy, driven by the region’s proximity to London and Heathrow. Of course, within the region sits the Park Royal Industrial Estate, which hosts over 500 food and drink businesses. These businesses produce around 30% of London’s food, with an estimated £8bn annual economic contribution. It is not for nothing that Park Royal is known as “London’s Kitchen”.

Food infrastructure like Park Royal is of the same strategic importance as energy or transport infrastructure – cities, London, cannot function without it. Park Royal is the UK’s largest industrial estate, providing employment for over 40,000 local people, most from surrounding boroughs. This makes it a place-based economic asset that should be at the centre of regional economic and innovation planning, not a peripheral logistics zone.

Food & drink manufacturing matters now more than ever. The food system is energy intensive, waste heavy, and under pressure from rising costs, regulation, and labour constraints.

At Brunel University of London, we are trying to realise some of these opportunities with the Park Royal Net Zero Food Systems project. Led by Brunel, with civic and sector partners, the project is explicitly focused on:

  • Energy reduction
  • Waste minimisation and valorisation
  • Digitalisation and automation
  • Low carbon production and logistics

The project frames net-zero as a way to reduce cost, improve resilience, and drive growth, not just cut emissions. We view net-zero as an industrial revolution: an industrial efficiency wave for food manufacturing, comparable to the automation of previous decades.

Energy and Sustainability Audit of a London Restaurant to Reduce Energy Consumption and Carbon Footprint

Beit El Zaytoun is a high‑occupancy restaurant operating in Park Royal from a well‑located, generously sized single‑storey premises refurbished for hospitality use, with mixed HVAC systems and long operating hours. The site consumes 413,895 kWh/year and emits ~75 tCO₂e, with gas supplying most energy (72%). Modelling indicates that fabric upgrades, LED lighting, ASHPs, and a modest PV array could reduce emissions by up to 24%, though overall performance is constrained by kitchen process loads, which make up 57% of total energy use, rising to 74% following building‑services improvements.

Heating electrification reduces gas use but increases electrical demand and faces practical challenges relating to grid capacity, external plant placement, and ventilation interactions. Fabric upgrades deliver incremental benefit, while on‑site PV potential (≈11 kWp) provides limited offsetting. Ultimately, decarbonisation is shaped more by the inherent energy intensity of catering operations than by building systems, limiting the impact of conventional retrofit measures.

Strategic Significance

Situated within the Park Royal industrial and food systems cluster, Beit El Zaytoun holds value beyond a single‑site retrofit. It serves as:

  • A real‑world case study of the decarbonisation limits in food‑led hospitality
  • A demonstrator for combined fabric, electrification, and renewables pathways
  • A platform to trial next‑generation low‑carbon catering technologies
  • A testbed for robust measurement and verification frameworks (TM54/IPMVP)

As such, the project addresses a broader systemic challenge: how to decarbonise energy‑intensive, process‑dominated commercial kitchens within the UK’s food supply chain.

Energy & CO2 Emissions Reduction at a Confectionery Business

Food manufacturing facilities across the UK typically feature expansive roof spaces – an underutilised asset with significant potential for solar photovoltaic (PV) energy generation. Harnessing this space for local renewable electricity production could play a pivotal role in reducing reliance on the national grid and advancing decarbonisation goals within the sector.

Despite this opportunity, adoption of solar PV remains limited. Key barriers include:

  • Property ownership constraints (e.g., leasehold vs. freehold)
  • Lease uncertainty, especially with short-term agreements
  • Concerns about performance, ROI, and long-term viability

This case study investigates the feasibility of installing a rooftop solar PV system at a confectionery manufacturing site in the Park Royal Industrial Estate, one of the UK’s most concentrated food production zones. The project aims to:

  • Lower electricity demand from the grid
  • Reduce operational energy costs
  • Cut carbon emissions

By addressing technical, economic, and regulatory uncertainties, this initiative seeks to build confidence in solar PV adoption and demonstrate a replicable model for sustainable energy transition in the food manufacturing sector.

Disruptive Development of Fully Compostable Materials to Replace Commodity Bio-Plastics

The environmental toll of plastic waste, especially from food packaging, has become a pressing issue. In Park Royal, one of the UK’s most significant food production and distribution hubs, the widespread use of non-degradable plastics like PET and PP exacerbates local and global sustainability challenges.
This project aims to revolutionise packaging within the Park Royal food supply chain by developing next-generation degradable thermoplastics.

These materials promise:

  • High gas barrier performance
  • Industrial compostability
  • Improved environmental outcomes

However, technical hurdles such as low melt strength and moisture sensitivity must be overcome to make these materials viable at scale.

In collaboration with Brunel University London, the initiative integrates expertise in materials science, polymer processing, and sustainable design. The goal is to deliver scalable, high-performance compostable packaging that aligns with Net Zero ambitions while meeting the rigorous standards of the food industry.

This project not only addresses a critical environmental need but also positions Park Royal as a leader in sustainable innovation.