Specialist Ready Meals Facility (High and Low Risk Conversion of an Existing Industrial Unit)

When our customer successfully won a new order for their speciality range of ready meals they needed their existing facility expanding and re-modelling urgently. With our inhouse team of CAD designers and refrigeration designers we were able to respond quickly and refine our customers draft design, ensuring industry best practice was adhered too and BRC accreditation easily achieved.

The turnkey project was like many ‘food’ projects fast track with no time for testing out subcontractors, our teams of inhouse trade operatives were quickly saw cutting the floor and installing the new drainage system within days of agreeing the layout. Our teams of resin floor layers seamlessly followed behind creating floor falls from polymer modified screed materials, working hand in hand with our fabrication teams installing concrete filled stainless steel kerbing. Once the kerbing was underway our insulated panel teams quickly started erecting hygienic composite panel walls and ceilings to form the new cold rooms, state of the art cooking areas, freezers and blast chillers.

Following directly behind the fabric element of the project the electrical, mechanical, ventilation and refrigeration commenced. Again, our inhouse trade operatives carried out the installation eliminating any possible delays and fragmentation of responsibility and quality. Specialist bespoke stainless steel ventilation canopies were installed, along with water, steam and gas services into the new cooking area in conjunction with odour control and fire suppression systems. Refrigeration systems were designed and installed for each freezer, blast chiller and temperature-controlled area, taking into account product volumes, desired pull down times and machinery heat loads, evaporator fins were precoated with a protective coating to maximise life expectancy.

The floors were finished with Food-CreteTM a Food Industry focused polyurethane hygienic resin to create a seamless junction between the new floors and the new stainless steel kerbing and finally during pre-planned out of hours shut down windows the dividing wall between the existing and new areas were removed.