DoorCo ramps up Doncaster hub as part of UK expansion drive

DoorCo has completed the latest phase of its investment in a 3.2-acre site in Doncaster, positioning the facility as a strategic hub for innovation, manufacturing and storage to support its Macclesfield headquarters.

The composite door supplier acquired the Thorne site in 2023 and has since integrated an additional 80,000 sq ft into its operations. The transition to a new goods-in storage facility is now complete, centralising inbound composite doors from Korea and Indonesia alongside FLiP glazing cassettes before onward distribution to Cheshire.

Mark Towers, strategy director at DoorCo, said the development would “expand UK operations and gain greater control over the future of our business”, reflecting a broader push for in-house efficiency and tighter oversight of stock and quality.

Initially established as the home of BRiTDOR – DoorCo’s 44mm and 48mm solid-core door range – the Doncaster site forms part of the company’s ambition to bring more manufacturing activity onshore. Subsequent investments have included an automated high-volume staining line designed to improve colour consistency across door designs and FLiP cassettes.

Further capital has been directed into new foaming lines for FLiP, DoorCo’s proprietary glazing cassette system. The company says the investment has underpinned record volumes, with more than 750,000 cassettes sold this year, cementing FLiP’s position as a leading system in the UK market. Expanded pre-foaming space and the introduction of a second shift have increased production capacity.

With incumbent tenants now vacated, DoorCo has also converted additional buildings to create a dedicated goods-in holding facility and installed more than 700 racking locations for cassette storage. The reconfiguration is designed to hold greater volumes of stock domestically, smoothing supply to Macclesfield and improving responsiveness to customers.

Operational oversight at Doncaster has been strengthened with the appointment of Chris Shooten as warehouse manager and the promotion of Ryan Rafferty to manufacturing manager, responsible for scaling BRiTDOR, FLiP and stained door output.

Alongside the logistics upgrade, DoorCo is developing an on-site innovation hub focused on the next generation of composite doors, as it prepares to enter 2026 with expanded capacity and a more vertically integrated UK footprint.