People Behind the Pour: David Barnett

The Greencroft Estate in Annfield Plain (DH9) is home to Lanchester Wines and Greencroft Bottling, sister businesses within the family-owned The Lanchester Group. Each is a leading business in its sector and together, they form one of the areas largest employers.. Consett Magazine has been given exclusive access to meet the people behind the scenes whose expertise and commitment keep these businesses running every day. 

Greencroft Bottling is a highly mechanised operation, where efficiency, safety and precision are essential. Keeping the bottling lines running smoothly requires constant attention and specialist skills, which is why the business has an in-house engineering department. We spoke to David Barnett, a multi-skilled maintenance engineer, about his role and career so far.

David’s skillset spans mechanical and electrical engineering, alongside welding and manufacturing.

“With welding and manufacturing, I can grind and cut my own parts and fabricate units we need in-house, whether that’s a frame, a table or a bespoke component,” he explains.

David holds both an Higher National Certificate (HNC) 4 in General Engineering and an HNC 4 in Welding and Manufacturing, qualifications he completed while working at Greencroft Bottling. After studying Level 3 General Engineering at New College Durham, he progressed to HNC Level 4 in both disciplines through the company.

“There are 11 or 12 modules in the General Engineering HNC, and I achieved a distinction in every one,” he says proudly.

Now 24, David joined Greencroft Bottling at 18 and has been with the business for nearly six years. The first four were spent as an apprentice, completing his apprenticeship in August 2024. During his first year, David worked as a pipe fitter, installing services for new production lines such as the Bag-in-Box line and other ancillary systems. He then moved into maintenance, where he has worked for the past five years.

Today, David’s role covers maintenance across the bottling lines and machinery, as well as welding projects when required.

“Our goal is to prevent breakdowns before they happen,”

he explains.

“But if something does go wrong, it’s my job to get the line running again and make sure production stays online.”

The engineering team follows Total Productive Maintenance (TPM) principles, focusing on preventing unplanned equipment failures. David spends most of his time in Greencroft Bottling, where the majority of the machinery is located, but the team also supports other departments when needed, including the Lanchester Wines warehouses.

“No two days are the same,” David says. “That’s what I love about the job.” 

A typical day starts with a shift handover to understand any outstanding issues. If nothing carries over, the team reviews scheduled maintenance tasks, often working on lines when they are offline. A Computerised Maintenance Management System (CMMS) is used to track maintenance hours, tasks and performance, with close coordination between engineering and management to plan work efficiently.

The team also carries out regular Gemba walks, a lean management practice meaning “go and see”. “We physically inspect the lines, listen for unusual noises, check for wear and tear and raise any issues early,” David explains. Health and safety concerns are addressed immediately, alongside technical faults.

Having recently completed his apprenticeship, David now helps support the next generation, with three apprentices currently working within the engineering function.

One of David’s most memorable projects was replacing a carousel bearing on one of the bottling fillers, a critical control point for food safety.

“It took about two weeks and was the first time we had carried out that job in-house,” he says.

“Previously, we would have used contractors, but as the engineering team has grown in confidence and capability, we’re now doing more complex work ourselves and relying less on external support.”

Another highlight was travelling to Italy to visit the original equipment manufacturers of Greencroft’s machinery. “It helped resolve a recurring issue, but it was also a great learning experience. It was my first time in technical meetings with other customers and suppliers.”

Originally from Lanchester, David balances work with an active life outside the factory. A former competitive swimmer who reached national level, he now plays for Consett Rugby Club and Lanchester Cricket Club, and he’s also an avid chess player.

So why does he enjoy working at Greencroft?

“I like being hands-on, being part of a community and having something different to tackle every day,”

he says.

“I enjoy problem-solving and keeping my brain active. I have ADHD, so this kind of environment suits me perfectly.”

If you would like to find out more about Greencroft Bottling and Lanchester Wines, visit their websites: www.greencroftbottling.com and www.lanchesterwines.co.uk