Location (AQA A Level Business): Exam Questions

Exam code: 7132

Syllabus Edition

First teaching 2026

First exams 2028

2 hours15 questions
1
6 marks

Source B: Portmeirion Group plc

Portmeirion Group plc makes and sells homeware and home fragrance. It is a public limited company listed on AIM, based in Stoke-on-Trent, and it owns six heritage brands: Spode, Portmeirion, Royal Worcester, Nambé, Pimpernel and Wax Lyrical. It has over 650 employees worldwide and the majority of them are in Stoke-on-Trent.

The last five years have been hard. Revenue reached £110.8 million in 2022 and then fell two years in a row, to £91.2 million in 2024, before holding at £91.1 million in 2025. Profit fell much further than revenue. Headline profit before tax was £8.0 million in 2022 and £1.0 million in 2024. The headline operating margin went from 7.8% in 2022 to 4.7% in 2023. Earnings for each share fell from 46.59p in 2022 to 8.04p in 2024, and the dividend from 15.50p to 1.50p. By the end of 2025 the group had net debt of £17.5 million, and although operations still generated cash, they generated only £0.5 million of it, against £2.1 million the year before.

The group sells in three main markets: the United Kingdom, North America and South Korea. North America is the largest of the three.

Portmeirion Group owns a factory in Stoke-on-Trent, but approximately 26% of its branded tableware is actually made there. The rest is bought in from suppliers, much of it in Asia. The company has a stated strategy called Made in Stoke-on-Trent and says it intends to increase the share it makes itself.

Something outside the business has pushed that plan along. When the United States introduced tariffs, orders that Portmeirion Group had sourced from Asia for the American market were cancelled, and the company decided to speed up parts of the Made in Stoke-on-Trent plan in response.

Source: Portmeirion Group plc annual results and interim statements, 2024 to 2026

Appendix E: Portmeirion Group plc revenue and headline profit before tax, indexed to 2022

Line chart of Portmeirion Group’s indexed revenue and headline profit before tax, 2020–2024 (2022 = 100). Revenue ranges from 79.3 to 100 then falls to 82.3; profit rises to 100 then drops sharply to 12.6.
Table of Portmeirion Group’s indexed revenue and headline profit before tax, with 2022 = 100: 2020–2024 values are revenue 79.3, 95.7, 100.0, 92.7, 82.3; profit 17.4, 89.9, 100.0, 37.9, 12.6.

Source: Portmeirion Group plc

Appendix G: Making tableware in Stoke-on-Trent compared with buying it from a supplier

  • Share of branded tableware made in the Stoke-on-Trent factory = 26%

  • Time to change a design or add a new product, made in Stoke-on-Trent = 4 weeks

  • Time to change a design or add a new product, bought from an overseas supplier = 20 weeks

  • Smallest order an overseas supplier will accept = 6 000 pieces

  • Smallest order the Stoke-on-Trent factory will run = 400 pieces

  • Average order to delivery time, Stoke-on-Trent = 3 weeks

  • Average order to delivery time, overseas supplier = 14 weeks

Source: Analyst

Analyse one way in which keeping a factory in Stoke-on-Trent, rather than buying all of its tableware from suppliers, might affect Portmeirion Group plc's costs.

2
6 marks

Source B: Tata Steel UK

Tata Steel UK is part of the Indian multinational Tata Steel. Its largest site in Britain is Port Talbot in south Wales, which for decades made steel from raw materials in two blast furnaces.

On 25 April 2024 the company confirmed that it would close those blast furnaces and spend £1.25 billion on an electric arc furnace on the same site instead. Blast furnace number 5 closed at the end of June 2024 and blast furnace number 4 closed on 30 September 2024, ending the making of primary steel at Port Talbot. The change put up to 2 800 jobs at risk and around 2 500 roles have since gone.

The two kinds of furnace work in completely different ways. A blast furnace turns imported iron ore and coking coal into new iron, runs continuously and cannot easily be turned down. An electric arc furnace melts scrap steel using electricity, can be started and stopped far more easily, emits far less carbon dioxide and needs far fewer people. It also depends on being able to buy enough scrap steel and on having a large enough electricity supply.

Steel was expected to be made at Port Talbot again in 2027 or 2028, but delays to the electricity grid connection mean the electric arc furnace is now not expected to be running until late 2028 or early 2029. In the meantime Port Talbot imports steel from other Tata Steel sites and rolls it there.

Port Talbot was chosen as a steel town for reasons that no longer all apply. It has a deep-water port built for importing iron ore, and rolling mills that are still in use. It does not sit close to where most of Britain's scrap steel is collected.

Source: Tata Steel UK announcements, 2024 to 2026

Appendix G: Two places to put the electric arc furnace

Comparison table of Option 1 Port Talbot and Option 2 new inland site: costs £1.25bn/£1.62bn; scrap distance 210/45 miles and annual transport £46m/£11m; other rows compare port, mills, grid dates, transferable employees and local jobs.
  • The electric arc furnace is planned to make 3.0 million tonnes of steel a year

Source: Analyst

Analyse one way in which being 210 miles from the main sources of scrap steel might affect Tata Steel UK's unit costs.

3
6 marks

Source B: Lush

Lush makes and sells fresh handmade cosmetics: bath bombs, soaps and shampoo bars, often sold loose and unwrapped. It is unusual among cosmetics companies because it makes almost everything it sells. Most beauty brands design a product and pay someone else to manufacture it. Lush manufactures and retails, and it says the freshness of what it makes is the reason people buy it.

In the year to 30 June 2025 turnover reached £736.2 million, up £63.5 million or 9.4%. Like-for-like turnover grew 8%, with retail shops up 7% and digital up 13%. The loss before tax narrowed sharply, from £52.1 million the year before to £6.7 million, and earnings before interest, tax, depreciation and amortisation returned to a profit of £28.4 million. A surge in the price of cocoa, which Lush uses in large quantities, held the result back.

At the end of June 2025 the group had 869 permanent shops, 665 of them run by the group rather than franchised, selling in 50 countries. It manufactured in six countries. During the year it spent about £6.5 million restructuring, bringing manufacturing in Europe and Canada together into fewer sites.

That restructuring is the question the business keeps returning to. Making everything in a small number of large factories is cheaper for each product made. Making it close to the shops that sell it keeps it fresh, which is what Lush tells customers it is selling. The two pull against each other, and both have an environmental consequence, which matters to a company that has built its brand partly on that.

Source: Lush audited accounts for the year ended 30 June 2025

Appendix F: Where Lush sells and where it makes

Table of Lush measures and figures: 869 permanent shops, 665 run by the group rather than franchised, sales in 50 countries, manufacturing in 6; 2025 restructuring consolidated European and Canadian manufacturing, costing about £6.5 million.

Source: Lush

Analyse one way in which manufacturing in six countries while selling in fifty might affect Lush's costs.

4
6 marks

Source B: Glanmor Dairy Ltd

Glanmor Dairy Ltd processes milk into cheese, butter and cream at a single creamery in Carmarthenshire. It employs 130 people, takes in 94 million litres of milk a year from 180 farms within about thirty miles, and in the year to March 2025 had revenue of £58 million and an operating profit of £2.3 million.

Milk is an unusual raw material. It arrives every day whether the creamery wants it or not, because cows do not stop. It cannot be stored for long before processing. And it is heavy and mostly water, so moving it is expensive: a tanker costs much the same to run whether the milk inside is worth a lot or a little.

The creamery is close to full. It can process 96 million litres a year and took 94 million last year, and the farms around it are producing more each year. Glanmor must either make its existing site bigger or build a second one.

If it builds a second creamery, where it goes matters. A site deep in the milk-producing country would sit close to the farms but a long way from the motorway network and from the supermarket depots that take the finished cheese. A site near the motorway would be the opposite: cheap to send the finished product out from, expensive to bring the raw milk into.

The managing director, Rhian Pugh, has asked for both questions to be answered: bigger here, or a second site, and if a second site, where.

Source: Glanmor Dairy Ltd

Appendix F: Two possible sites for a second creamery

Comparison table for 94 million litres of milk: Site A and B haulage costs are £0.030 and £0.055 per litre, with milk travelling 14 and 46 miles. Site B’s extra annual haulage cost is shown as “?”.

Source: Analyst

Analyse one way in which building the second creamery beside the motorway might affect Glanmor Dairy Ltd's costs.

5
6 marks

Source B: Kielder Timber Products Ltd

Kielder Timber Products Ltd runs a sawmill in Northumberland, fourteen kilometres from the nearest gate into the forest it buys most of its logs from. It cuts fencing, pallet wood and construction timber, employs 150 people and had revenue of £24.6 million in the year to March 2025, with an operating profit of £1.9 million.

The mill is full. It takes in 90 000 cubic metres of logs a year and runs for 110 hours out of a possible 112 every week. Whatever does not come out as sawn timber is sold on as chips and sawdust to a board mill and a biomass plant, so very little of the log is wasted, but the amount that leaves as timber is the number the directors watch.

Demand is the problem rather than the solution. Housebuilding and fencing orders have grown every year since 2021, and last year Kielder turned away 11 000 cubic metres of orders it had no way of cutting. A second mill would roughly double what the company can produce, and would lower the cost of every cubic metre, because logs bought in larger quantities cost less and the fixed costs would be spread over twice the output.

Where to put it is the difficult part. One site sits beside the existing mill, a short haul from the forest and run by the team that is already there, but it is expensive to build and the planning application is being contested. The other is a former colliery site sixty-five kilometres south, cheaper to build, grant-aided, already consented and much closer to customers, but every log would travel five times as far to reach it.

Source: Kielder Timber Products Ltd

Appendix H: Two possible sites for the second mill

Comparison table for 9,000 lorry loads of logs a year: Site A is 14 km from a forest gate and charges £95 per load; Site B is 78 km away and charges £190. Annual log-delivery cost is £855 000 for A and £1 710 000 for B.

Source: Analyst

Analyse one way in which a site 78 kilometres from the nearest forest gate might affect Kielder Timber Products Ltd's costs.

6
6 marks

Source B: Hallerton Cold Stores Ltd

Hallerton Cold Stores Ltd keeps frozen food for other people. It runs one store near Hull with 18 000 pallet spaces, holds it at about minus 24 degrees Celsius every hour of every day, and moves 1 900 pallets in and out daily. It employs 110 people, had revenue of £14.2 million in the year to March 2025 against operating costs of £12.4 million, and made an operating profit of £1.8 million.

What makes the business unlike a warehouse is electricity. Keeping 18 000 pallet spaces that cold cost £4 464 000 last year, which is by a wide margin the largest thing the company spends money on, more than it spends on wages. The bill also moves with the weather: a pallet space uses about 83 kilowatt hours in July and 58 in January.

The store is nearly full. It runs at 92% of its pallet spaces on average, picks 97.8% of pallets inside the hour it promises, and has been outside its agreed temperature range three times in a year. The oldest refrigeration plant is nineteen years old.

Customers want more space than Hallerton has, so a second store is agreed in principle. Two things are not. One is where to put it: beside the existing store, where the grid connection exists and the night shift could be shared, or in the East Midlands, far closer to the three customers who provide over half the revenue. The other is what to build: the same again, or something that uses a third less electricity for every pallet space and costs several million pounds more.

Source: Hallerton Cold Stores Ltd

Appendix G: A second store, and where it could go

Two tables. Now and with a second store: stores, 1 now and 2 with a second store; pallet spaces, 18 000 and 30 000; employees, 110 and 178; operating costs each year, £12.4m and £19.8m; operating cost for each pallet space, £689 and £660; managers needed, 7 and 12; customers it could serve, 31 and 44. Site A, beside the existing store near Hull, and Site B, a site in the East Midlands: cost to build, £17.4m and £21.2m; electricity price for each kilowatt hour, 30.2p and 28.6p; average distance to the three largest customers, 164 km and 71 km; whether it can share the existing night shift and management, yes and no; whether a grid connection is already in place, yes for Site A and no for Site B, which needs 14 months to arrange; local people with cold-store experience, many and few; share of customers who said they would use it, 61% and 88%.

Source: Analyst

Analyse one way in which a site 71 kilometres from its three largest customers rather than 164 might affect Hallerton Cold Stores Ltd.

7
6 marks

Source B: Calder Vale Coffee Roasters Ltd

Calder Vale Coffee Roasters Ltd roasts coffee for cafés and food retailers from one roastery near Skipton. It employs 84 people, roasts about 1 850 tonnes of green beans a year, and in the year to March 2025 had revenue of £19.6 million and an operating profit of £1.35 million. It has been trading for twenty-nine years and supplies 240 customers.

The beans come from eleven co-operatives in four countries. Calder Vale pays £4 920 a tonne when the market price is £4 500, not under any certification scheme but under its own agreement with the growers, and it tells customers so. It visited seven of the eleven co-operatives last year and can name the farm of origin for 83% of what it buys.

Roasting coffee is a gas-fired business. Of the 2 775 tonnes of carbon dioxide equivalent the company produced last year, the largest share came from the three roasters themselves rather than from shipping beans halfway round the world. The oldest roaster is twenty-two years old.

Packaging is the other half of the environmental question, and the harder half to move. Forty-six per cent of what Calder Vale packs can be recycled at home and none of it is reused, because a bag of coffee is normally thrown away once it is empty.

A second roastery has been agreed in principle, and the board also has to decide what to do about the emissions it already has.

Source: Calder Vale Coffee Roasters Ltd

Appendix E: Calder Vale Coffee Roasters Ltd selected data, year to March 2025

Selected data table: the average distance to Calder Vale’s twenty largest customers is 212 kilometres; 38% of customers are within 150 kilometres of the roastery.

Source: Calder Vale Coffee Roasters Ltd

Analyse one way in which being an average of 212 kilometres from its twenty largest customers might affect Calder Vale Coffee Roasters Ltd.

1
9 marks

Source B: Portmeirion Group plc

Portmeirion Group plc makes and sells homeware and home fragrance. It is a public limited company listed on AIM, based in Stoke-on-Trent, and it owns six heritage brands: Spode, Portmeirion, Royal Worcester, Nambé, Pimpernel and Wax Lyrical. It has over 650 employees worldwide and the majority of them are in Stoke-on-Trent.

The last five years have been hard. Revenue reached £110.8 million in 2022 and then fell two years in a row, to £91.2 million in 2024, before holding at £91.1 million in 2025. Profit fell much further than revenue. Headline profit before tax was £8.0 million in 2022 and £1.0 million in 2024. The headline operating margin went from 7.8% in 2022 to 4.7% in 2023. Earnings for each share fell from 46.59p in 2022 to 8.04p in 2024, and the dividend from 15.50p to 1.50p. By the end of 2025 the group had net debt of £17.5 million, and although operations still generated cash, they generated only £0.5 million of it, against £2.1 million the year before.

The group sells in three main markets: the United Kingdom, North America and South Korea. North America is the largest of the three.

Portmeirion Group owns a factory in Stoke-on-Trent, but approximately 26% of its branded tableware is actually made there. The rest is bought in from suppliers, much of it in Asia. The company has a stated strategy called Made in Stoke-on-Trent and says it intends to increase the share it makes itself.

Something outside the business has pushed that plan along. When the United States introduced tariffs, orders that Portmeirion Group had sourced from Asia for the American market were cancelled, and the company decided to speed up parts of the Made in Stoke-on-Trent plan in response.

Source: Portmeirion Group plc annual results and interim statements, 2024 to 2026

Appendix F: Portmeirion Group plc revenue by region

Grouped bar chart of Portmeirion Group revenue by region in £ millions, in 2022 and 2025: United Kingdom 28.3 and 32.6; North America 48.9 and 35.4; South Korea 26.7 and 14.5; Rest of the World 7.0 and 8.5. The vertical axis runs from 0 to 55.
Table of Portmeirion Group revenue by region in 2022 and 2025, with the change: United Kingdom £28.3m and £32.6m, up 15.4%; North America £48.9m and £35.4m, down 27.7%; South Korea £26.7m and £14.5m, down 45.5%; Rest of the World £7.0m and £8.5m, up 22.5%; total £110.8m and £91.1m, down 17.8%.

Source: Portmeirion Group plc

Assess the impact of United States tariffs on Portmeirion Group plc's decisions about where its products are made.

2
9 marks

Source B: Lush

Lush makes and sells fresh handmade cosmetics: bath bombs, soaps and shampoo bars, often sold loose and unwrapped. It is unusual among cosmetics companies because it makes almost everything it sells. Most beauty brands design a product and pay someone else to manufacture it. Lush manufactures and retails, and it says the freshness of what it makes is the reason people buy it.

In the year to 30 June 2025 turnover reached £736.2 million, up £63.5 million or 9.4%. Like-for-like turnover grew 8%, with retail shops up 7% and digital up 13%. The loss before tax narrowed sharply, from £52.1 million the year before to £6.7 million, and earnings before interest, tax, depreciation and amortisation returned to a profit of £28.4 million. A surge in the price of cocoa, which Lush uses in large quantities, held the result back.

At the end of June 2025 the group had 869 permanent shops, 665 of them run by the group rather than franchised, selling in 50 countries. It manufactured in six countries. During the year it spent about £6.5 million restructuring, bringing manufacturing in Europe and Canada together into fewer sites.

That restructuring is the question the business keeps returning to. Making everything in a small number of large factories is cheaper for each product made. Making it close to the shops that sell it keeps it fresh, which is what Lush tells customers it is selling. The two pull against each other, and both have an environmental consequence, which matters to a company that has built its brand partly on that.

Source: Lush audited accounts for the year ended 30 June 2025

Appendix F: Where Lush sells and where it makes

Table of Lush measures and figures: 869 permanent shops, 665 run by the group rather than franchised, sales in 50 countries, manufacturing in six, restructuring to fewer European and Canadian sites costing about £6.5 million.

Source: Lush

Appendix H: Two ways of organising Lush's manufacturing

Products made each year = 118 million

Comparison table of two ways of organising Lush's manufacturing. Option 1, fewer, larger factories, against Option 2, make close to each market: 3 factories against 11; one-off restructuring cost £6.5m against £0; cost of making each product £2.10 against £2.46; annual cost of making the products £247.8m against £290.3m; average time from making to the shop shelf 19 days against 6 days; share of products moved between countries 61% against 12%; carbon emitted moving products each year 24 100 tonnes against 7 300 tonnes; smallest run a factory will accept 2 400 units against 600 units.

Source: Analyst

Assess whether Lush should manufacture close to the markets it sells in.

3
9 marks

Source B: Glanmor Dairy Ltd

Glanmor Dairy Ltd processes milk into cheese, butter and cream at a single creamery in Carmarthenshire. It employs 130 people, takes in 94 million litres of milk a year from 180 farms within about thirty miles, and in the year to March 2025 had revenue of £58 million and an operating profit of £2.3 million.

Milk is an unusual raw material. It arrives every day whether the creamery wants it or not, because cows do not stop. It cannot be stored for long before processing. And it is heavy and mostly water, so moving it is expensive: a tanker costs much the same to run whether the milk inside is worth a lot or a little.

The creamery is close to full. It can process 96 million litres a year and took 94 million last year, and the farms around it are producing more each year. Glanmor must either make its existing site bigger or build a second one.

If it builds a second creamery, where it goes matters. A site deep in the milk-producing country would sit close to the farms but a long way from the motorway network and from the supermarket depots that take the finished cheese. A site near the motorway would be the opposite: cheap to send the finished product out from, expensive to bring the raw milk into.

The managing director, Rhian Pugh, has asked for both questions to be answered: bigger here, or a second site, and if a second site, where.

Source: Glanmor Dairy Ltd

Appendix F: Two possible sites for a second creamery

Table comparing two sites for a creamery handling 94 million litres of milk a year, Site A in the milk country against Site B beside the motorway: average distance milk travels to the creamery 14 miles against 46 miles; haulage cost for each litre of milk in £0.030 against £0.055; extra annual haulage cost of Site B not provided; distance to the nearest supermarket depot 88 miles against 21 miles; cost of sending finished product out each year £1.84m against £0.92m; cost of the land and building £18.6m against £24.2m; people within 30 minutes who could work there 4 200 against 61 000; local council grant available £2.4m against none.

Source: Analyst

Appendix G: What happens to a litre of milk

Bar chart of cost per litre in GBP, with a vertical scale from £0 to £0.45: buying milk £0.38, haulage £0.03, processing £0.14, packaging £0.05 and distribution £0.02.
Two tables: per-litre costs are milk £0.38, haulage £0.03, processing £0.14, packaging £0.05, distribution £0.02, total £0.62. Other figures: under 36 hours, milk is 61% of cost, cheese held 21 days.

Source: Analyst

Assess which of the two sites Glanmor Dairy Ltd should choose for a second creamery.

Calculate the extra annual haulage cost of choosing Site B to support your answer.

4
9 marks

Source A: Monzo

Monzo is a digital bank with no branches. In the year to 31 March 2025 revenue passed £1 billion for the first time, rising 48% to £1.2 billion, and adjusted profit before tax went from £13.9 million to £113.9 million. It now has more than 12 million customers, including about 625 000 business customers. Of the 2.4 million customers who joined during the year, more than two thirds came by word of mouth.

It grew up on an unusually open way of working. Most internal channels could be read by anybody in the company, decisions were argued out where everyone could see them, and employees were expected to say when they thought something was wrong. That was straightforward when there were a few hundred people.

There are now 5 275, a rise of 34% in a year, and more than half of them have been there under two years. The culture survey has moved with the size. The share who say they can see the decisions that affect them being made has fallen from 84% to 46%, and the share who say they can raise a concern and be heard from 88% to 63%.

Two other things have changed. Monzo is a regulated bank, so anything affecting customers' money now has to follow a formal process rather than a conversation in a channel, and some information cannot be visible to 5 275 people at all. And 61% of employees work mainly from home, across three offices, with 72% on London contracts.

The board is preparing to launch in two more countries and wants to know what it is prepared to change.

Source: Monzo Bank Limited Annual Report for the year ended 31 March 2025

Appendix C: How Monzo is organised and where its people work

Monzo organisational measures: 4 levels from chief executive to new engineer; about 180 squads, 8 people each; about 2 600 customer-operations staff; desk costs £9 400 London, £5 100 elsewhere; 4 annual training days; 58% manager roles filled internally.

Source: Analyst

Assess whether Monzo still needs 72% of its employees on London contracts.

5
9 marks

Source B: Hallerton Cold Stores Ltd

Hallerton Cold Stores Ltd keeps frozen food for other people. It runs one store near Hull with 18 000 pallet spaces, holds it at about minus 24 degrees Celsius every hour of every day, and moves 1 900 pallets in and out daily. It employs 110 people, had revenue of £14.2 million in the year to March 2025 against operating costs of £12.4 million, and made an operating profit of £1.8 million.

What makes the business unlike a warehouse is electricity. Keeping 18 000 pallet spaces that cold cost £4 464 000 last year, which is by a wide margin the largest thing the company spends money on, more than it spends on wages. The bill also moves with the weather: a pallet space uses about 83 kilowatt hours in July and 58 in January.

The store is nearly full. It runs at 92% of its pallet spaces on average, picks 97.8% of pallets inside the hour it promises, and has been outside its agreed temperature range three times in a year. The oldest refrigeration plant is nineteen years old.

Customers want more space than Hallerton has, so a second store is agreed in principle. Two things are not. One is where to put it: beside the existing store, where the grid connection exists and the night shift could be shared, or in the East Midlands, far closer to the three customers who provide over half the revenue. The other is what to build: the same again, or something that uses a third less electricity for every pallet space and costs several million pounds more.

Source: Hallerton Cold Stores Ltd

Appendix E: Hallerton Cold Stores Ltd selected data, year to March 2025

Table of selected data: 110 employees; 18 000 pallet spaces; revenue £14.2m; operating costs £12.4m; operating profit £1.8m; energy cost £4 464 000; temperature about minus 24 degrees Celsius; 31 customers; 54% of revenue from three largest customers.

Source: Hallerton Cold Stores Ltd

Appendix G: A second store, and where it could go

Two tables compare one versus two stores and two sites. Annual operating costs rise from £12.4m to £19.8m; electricity costs 30.2p per kilowatt-hour at Hull and 28.6p in the East Midlands.

Source: Analyst

Assess the importance of the price of electricity to Hallerton Cold Stores Ltd's choice of site.

Calculate Hallerton Cold Stores Ltd's unit cost for each pallet space to support your answer.

1
15 marks

Source B: Tata Steel UK

Tata Steel UK is part of the Indian multinational Tata Steel. Its largest site in Britain is Port Talbot in south Wales, which for decades made steel from raw materials in two blast furnaces.

On 25 April 2024 the company confirmed that it would close those blast furnaces and spend £1.25 billion on an electric arc furnace on the same site instead. Blast furnace number 5 closed at the end of June 2024 and blast furnace number 4 closed on 30 September 2024, ending the making of primary steel at Port Talbot. The change put up to 2 800 jobs at risk and around 2 500 roles have since gone.

The two kinds of furnace work in completely different ways. A blast furnace turns imported iron ore and coking coal into new iron, runs continuously and cannot easily be turned down. An electric arc furnace melts scrap steel using electricity, can be started and stopped far more easily, emits far less carbon dioxide and needs far fewer people. It also depends on being able to buy enough scrap steel and on having a large enough electricity supply.

Steel was expected to be made at Port Talbot again in 2027 or 2028, but delays to the electricity grid connection mean the electric arc furnace is now not expected to be running until late 2028 or early 2029. In the meantime Port Talbot imports steel from other Tata Steel sites and rolls it there.

Port Talbot was chosen as a steel town for reasons that no longer all apply. It has a deep-water port built for importing iron ore, and rolling mills that are still in use. It does not sit close to where most of Britain's scrap steel is collected.

Source: Tata Steel UK announcements, 2024 to 2026

Appendix E: What changed at Port Talbot

Timeline of what changed at Port Talbot: 25 April 2024, Tata Steel confirms a £1.25 billion investment in an electric arc furnace at Port Talbot; end of June 2024, blast furnace number 5 closes; 30 September 2024, blast furnace number 4 closes, ending the making of primary steel at Port Talbot; 2024 onwards, up to 2 800 jobs at risk and around 2 500 roles have gone; 2024 to 2028, steel is imported from other Tata Steel sites and rolled at Port Talbot; originally planned, steel to be made at Port Talbot again in 2027 or 2028; now expected, late 2028 or early 2029, because of delays to the electricity grid connection.

Source: Tata Steel UK

Appendix G: Two places to put the electric arc furnace

Table comparing Option 1, Port Talbot, with Option 2, a new inland site: cost to build £1.25bn and £1.62bn; deep-water port already on the site, yes and no; rolling mills already on the site, yes, and no, they would have to be built; distance to the main sources of scrap steel 210 miles and 45 miles; transport cost of scrap each year £46m and £11m; extra transport cost of Option 1 over ten years, not provided for Option 1 and not applicable for Option 2; electricity grid connection available late 2028 and 2031; existing employees who could transfer 1 500 and 240; share of the local area's jobs that depend on the steelworks 7% and under 1%.
  • The electric arc furnace is planned to make 3.0 million tonnes of steel a year

Source: Analyst

Tata Steel UK had to decide where to build its electric arc furnace:

Option 1: at Port Talbot

Option 2: at a new inland site closer to the scrap steel

Evaluate both options and recommend which one Tata Steel UK should have chosen.

Calculate the extra transport cost of Option 1 over ten years to support your answer.

2
15 marks

Source B: Kielder Timber Products Ltd

Kielder Timber Products Ltd runs a sawmill in Northumberland, fourteen kilometres from the nearest gate into the forest it buys most of its logs from. It cuts fencing, pallet wood and construction timber, employs 150 people and had revenue of £24.6 million in the year to March 2025, with an operating profit of £1.9 million.

The mill is full. It takes in 90 000 cubic metres of logs a year and runs for 110 hours out of a possible 112 every week. Whatever does not come out as sawn timber is sold on as chips and sawdust to a board mill and a biomass plant, so very little of the log is wasted, but the amount that leaves as timber is the number the directors watch.

Demand is the problem rather than the solution. Housebuilding and fencing orders have grown every year since 2021, and last year Kielder turned away 11 000 cubic metres of orders it had no way of cutting. A second mill would roughly double what the company can produce, and would lower the cost of every cubic metre, because logs bought in larger quantities cost less and the fixed costs would be spread over twice the output.

Where to put it is the difficult part. One site sits beside the existing mill, a short haul from the forest and run by the team that is already there, but it is expensive to build and the planning application is being contested. The other is a former colliery site sixty-five kilometres south, cheaper to build, grant-aided, already consented and much closer to customers, but every log would travel five times as far to reach it.

Source: Kielder Timber Products Ltd

Appendix G: What a second mill would change

Table of what a second mill would change, now and with a second mill: sawmills 1 and 2; logs taken in each year 90 000 and 180 000 cubic metres; sawn timber produced each year 54 000 and 108 000 cubic metres; employees 150 and 265; cost of buying one cubic metre of logs £62 and £58; fixed costs each year £4.1m and £7.0m; fixed cost for each cubic metre of sawn timber £75.93 and £64.81; orders Kielder could not meet 11 000 and 0 cubic metres; managers needed 9 and 17.

Source: Analyst

Appendix H: Two possible sites for the second mill

Comparison table of Sites A and B: 9 000 lorry loads yearly; Site A’s log haulage is £95 per load (annual cost not provided), versus £190 (£1.71m annually) for Site B; finished-timber delivery costs £1.24m and £790 000 respectively.

Source: Analyst

Kielder Timber Products Ltd is considering two sites for its second mill:

Site A: beside the existing mill in Northumberland

Site B: a former colliery site 65 kilometres south

Evaluate both sites and recommend which one Kielder Timber Products Ltd should choose.

Calculate the annual cost of bringing logs in to Site A to support your answer.

3
15 marks

Source B: Hallerton Cold Stores Ltd

Hallerton Cold Stores Ltd keeps frozen food for other people. It runs one store near Hull with 18 000 pallet spaces, holds it at about minus 24 degrees Celsius every hour of every day, and moves 1 900 pallets in and out daily. It employs 110 people, had revenue of £14.2 million in the year to March 2025 against operating costs of £12.4 million, and made an operating profit of £1.8 million.

What makes the business unlike a warehouse is electricity. Keeping 18 000 pallet spaces that cold cost £4 464 000 last year, which is by a wide margin the largest thing the company spends money on, more than it spends on wages. The bill also moves with the weather: a pallet space uses about 83 kilowatt hours in July and 58 in January.

The store is nearly full. It runs at 92% of its pallet spaces on average, picks 97.8% of pallets inside the hour it promises, and has been outside its agreed temperature range three times in a year. The oldest refrigeration plant is nineteen years old.

Customers want more space than Hallerton has, so a second store is agreed in principle. Two things are not. One is where to put it: beside the existing store, where the grid connection exists and the night shift could be shared, or in the East Midlands, far closer to the three customers who provide over half the revenue. The other is what to build: the same again, or something that uses a third less electricity for every pallet space and costs several million pounds more.

Source: Hallerton Cold Stores Ltd

Appendix F: What the store is judged on

Energy used for each pallet space, kilowatt hours

Line graph of monthly energy used per pallet space: kilowatt hours rise from 58 in January to 83 in July, then fall to 63 in November. The vertical axis ranges from 0 to 90 kilowatt hours.
Table of store measures: 18,000 pallet spaces, 16,560 full (92%); 1,900 pallets moved daily; 97.8% picked within an hour; 24-hour operation; three temperature breaches; annual energy use 820 kilowatt-hours per pallet space; plant aged 19 years.

Source: Analyst

Appendix G: A second store, and where it could go

Comparison tables show the second store: 30,000 pallet spaces, 178 employees, £19.8m annual costs, £660 per space, 12 managers and 44 customers. Sites A/B: £17.4m/£21.2m build, 30.2p/28.6p electricity, 164/71 km, shared staff and grid yes/no, expertise many/few, customer use 61%/88%.

Source: Analyst

Hallerton Cold Stores Ltd is considering two sites for its second store:

Site A: beside the existing store near Hull

Site B: a site in the East Midlands

Evaluate both sites and recommend which one Hallerton Cold Stores Ltd should choose.