Leading the way in manufacturing

To take manufacturing to the next level, we’ve embarked on a full redevelopment of our 14.5-acre site. By relocating our Parts Direct operation to North Bristol and our Large Panel Laminating Plant to North Somerset, we’ve created the space needed to expand and modernise further. An example of this is the construction of our purpose-built Replenishment Centre, that allows us to house the thousands of components required to create our caravans, motorhomes and campervans under one roof. One of the latest upgrades includes the installation of five new CNC machines and two fully automated storage and retrieval systems, delivering even greater accuracy in the production of components such as cabinetry and internal panels.

With this continued investment, and the expertise of our dedicated team, we’re confident Bailey leisure vehicles will remain a familiar sight on roads across the UK for many years to come.

This is how caravans are made

Follow the manufacturing process of Bailey caravans from start to finish and watch how every Bailey is assembled in our site in South Liberty Lane in Bristol.

Our Large Panel Laminating Plant

The Large Panel Laminating Plant in Clevedon is where we make the floors, sides and ceilings for Bailey caravans, motorhomes and campervans. This fully automated plant is capable of manufacturing up to 1,500 bodyshell panels a week, or one fully machined panel every 12 minutes.

The manufacturing process begins with the assembly of the panel components on a laser-guided jig for improved accuracy and consistency. This assembly is then bonded together using a bead application system. A water-based agent is used to provide a superior bond before individually loaded into separate tiers on a 4-tier vacuum press. Once the lamination process is complete, the resulting panels are machined on a fully automated CNC machine.

How are caravan, motorhome & campervan furniture panels made?

The Small Panel Manufacturing Plant in Bristol is where we make the furniture panels for our Bailey caravans, motorhomes and campervans. This fully automated plant is capable of manufacturing up to 5,800 panels a day (or one fully machined panel every 10 seconds) which equates to 25 full furniture sets (on average one vehicle requires 230 individual panels).

The plant consists of five CNC machines are arranged in a high-efficiency line which is  integrated with an automated palletised plywood handler. This intelligent storage and retrieval system automatically shuffles the different finishes and thicknesses of timber sheets to feed each machine exactly what it needs. The whole process is fully mechanised which not only optimizes accuracy and efficiency but also creates a safer and more sustainable working environment

How life is really like working at Bailey