A Shropshire-based manufacturer, with a proud 50-year heritage, is embarking on a new chapter of growth, completing a state-of-the-art manufacturing site to support a range of high-profile customer projects, including a Netflix film and television set.
Bucknell-based family business, Hornsey Steel Panels and Sections’ custom solutions are proving invaluable to major industry players, such as UK Netflix productions The Crown and Bridgerton.
Most recently, Samuel Hornsey, who took over as Company Director when his father Mark stepped down in 2014, led the construction of a state-of-the-art, 24-bay facility, creating an operational space that is 2.5 times larger than its previous premises.
The development was made possible by a £1.5m Clean Growth Financing Initiative (CGFI) development loan from Lloyds, a product specifically tailored to support sustainable growth projects. Additionally, a trade finance facility facilitated the import of a £1.3m advanced manufacturing machine from Taiwan, further expanding production capabilities. When the new machine is installed in February 2025, an £800,000 hire purchase facility will repay the trade line, streamlining the financing of this key equipment.
The new manufacturing site, previously an old coal yard, is purpose-built to improve operations and sustainability. Designed with a long, linear layout on a former coal yard, the facility accommodates the production of metal roofing panels and structural steel products. By quadrupling its product range, Hornsey Steel Panels and Sections has enhanced its ability to serve diverse client needs, from local walk-in customers to large-scale construction projects managing high-profile contracts such as a Netflix studio build.
Hornsey Steel Panels and Sections’ commitment to sustainability is a core part of its growth strategy. The new site is equipped with energy-efficient lighting, and the company is finalising plans with Shropshire and Worcestershire Council to install a 104 kW solar array. These measures ensure the facility achieves an A-rated EPC (Energy Performance Certificate) while minimising its environmental footprint.
In addition, 70% of the building’s materials were manufactured in-house, showcasing Hornsey Steel Panels and Sections’ ability to integrate its expertise into the construction process. This innovative approach also reduced costs and bolstered sustainability during development.
The company’s expansion has unlocked job opportunities at the firm, bringing its workforce to 30, with 80% of employees based locally within 15 miles of the site. This includes a new Commercial Director whose expertise will support the company’s ambitious plans.
With the new facility and equipment, Hornsey Steel Panels and Sections has already increased operational efficiency by 25% and expects to increase its turnover to up to £25m this year. The increased space is also helping the firm to manoeuvre raw materials and finished goods more easily, boosting day-to-day efficiency. The expanded product range enables the company to offer a comprehensive suite of services, positioning it as a one-stop shop for structural steel and roofing solutions.
Samuel Hornsey, Company Director of Hornsey Steel Panels and Sections, said: “Our new manufacturing site marks a transformative step for the business. This expansion enables us to meet growing customer demand, significantly broaden our product range, and improve efficiency across the board.
“This investment is about much more than growth – it’s about sustainability, innovation, and supporting the workforce in our local community. Lloyds’ partnership has been invaluable, from securing the development loan to facilitating the import of our new equipment, and we’re excited to see how this investment propels our business forward.”
Jason Gregory, Relationship Manager at Lloyds, commented: “Hornsey Steel Panels and Sections is an inspiring example of a forward-thinking, family-run British manufacturer. It’s been a pleasure to support them in their expansion and sustainability initiatives.
“By combining development finance, trade facilities, and hire purchase solutions, we’ve been able to offer a comprehensive funding package that aligns with their ambitions. We’re excited to see how their new facilities and equipment will further drive success.”
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