Purpose-designed Facility for E-liquid Manufacture to Rapidly Increase Production Capacity

Totally Wicked had a requirement for a purpose-designed fluid production and technical facility which would increase the company’s capacity to over 10 million bottles of premium quality e-liquid every year for the UK, USA and worldwide markets. 

A key project requirement was to ensure as little disruption as possible to Totally Wicked’s operations and the surrounding residential community on a highly constrained site in Blackburn.

The building was constructed off site using a Portakabin Design and Build solution to radically shorten the programme time and reduce disruption.

The approach reduced the build time for the facility to just four months to give Totally Wicked the benefit of earlier occupation. This allowed production capacity to be increased and facilitated the company’s expansion. The building was handed over on time and on budget.

“We needed this building to help us meet the growing demand for our products both in the UK and for export markets.  It is a cutting edge facility for e-liquid production.”

“We chose an off-site solution because the brownfield site we wanted to develop is very constrained and it was critical to have as little interruption to our operations and to neighbouring properties as possible. The benefits of off-site construction far exceeded those of site-based construction – we could have much less plant and equipment on site, the programme was much shorter, and disruption was minimised.”

“Following completion we are now ideally placed to take the business to the next level, increasing production in a very clean, modern environment. The finished building fits in really well with our corporate image and we would definitely recommend the approach and Portakabin to other businesses looking to expand their facilities.”

Stuart Mercer, Operations Director at Totally Wicked

The building was finished in anthracite grey with striking chilli red stripes to reflect the client’s strong corporate image. Around 30 people work from the new facility to meet the growing demand for Totally Wicked’s e-liquid products.

Portakabin was principal contractor for the project and managed foundations, design, construction, and landscaping. The building has a high performance pre-installed concrete floor at ground floor level to provide a robust, lasting and clean finish for the production areas. The landscaping included tree planting and an external break-out space for staff.

Project Challenges:

  • This was a challenging, sloping site which required complex excavations and the construction of a 5m high gabion stone retaining wall to meet planning restrictions for the building height.
  • The building has a cold room which had to meet stringent standards for the storage of nicotine solutions, including a high level of insulation.
  • The site was very constrained and immediately adjacent to a main road requiring detailed logistical planning for the building installation phase.

Building Location


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