Freezer Storage for Carbon Fibre, Rochdale

Tygavac

Background

Part of Airtech Advanced Materials Group, Tygavac approached us to design & build storage for carbon fibre, which they use during manufacturing. It has an extended lifespan when stored below -20C. Due to our extensive experience in this area, we were selected as their partner for this important project.

Requirement

Full turnkey 470m³ coldstore with refrigeration, pallet racking, concrete floor & protection system.

Solution

The insulated store was built using 125mm Kingspan PIR panels finished in 120 Micron PVC Laminate. The door is an insulated sliding door suitable for forklift truck access. The floor comprises an underfloor heater, insulation & reinforced concrete. The refrigeration consists of two J & E Hall condensing units, connected to two Searle evaporators located high in the freezer. We installed all the mechanical, plumbing and electrical works, including all testing and commissioning.

Finally, we installed an innovative RDM data manager which enables the client to monitor and control the room’s performance. This can be done either locally or remotely using a desktop computer or an app installed on a mobile device.

New technology enables control of the store temperature remotely

Gary Howells, Project Manager

Location	Rochdale
Building Use	Storage for Carbon Fibre Destined For Aerospace Industry
Panel Cores	PIR Panels
Panel Supplier	Kingspan
Panel Thickness	Walls 125mm, Ceiling 125mm
Panel Facing	White Cleanable Laminated Food-Safe Finish
Panel Requirements	310 m²
Doors/ Floors	Insulated Freezer Sliding Door, Low Voltage Modular Heater-Mat
Technology	RDM Data Manager For Remote Monitoring and Control of Room Performance

Firewall & A Non-Fire-Rated Enclosure

Fit-Out Contractor

Background

Stancold were approached by an office fit-out company requiring assistance with the composite partitioning scope of their works for a leading confectionery & sweets manufacturer’s new facilities in Cheshire.

Following a successful tender process, we were awarded the contract to deliver an 84 metre long, 120-minute fire-rated wall and the construction of a non-fire-rated enclosure for a processing room.

Process

Our sales & design teams consulted the client’s architects to propose a solution accommodating the existing steelworks structure. Following a site visit conducted to advise on possible up-rating on fire-rated elements already in place, Stancold settled on a vertically oriented wall made of two stacked rows of Eurobond panels.

Project Delivery

The Stancold team liaised with the client to coordinate our visits in line with other works on site, allowing for flexible delivery of the overall project.

Having built the whitewall, our team returned to the site a month later to construct a 150 m² enclosure to contain a starch-processing plant, keeping it separate from the rest of the facility, given the flammable nature of the matter.

A great showcase of how we can help a contractor deliver their turnkey project

Rob White, Stancold Project Manager

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Sample-testing Lab Coldrooms

Adcock Refrigeration

Background

Based on a long-standing partnership, Stancold’s preferred refrigeration supplier, Adcock Refrigeration, commissioned two food-safe storage areas for an end user specialising in testing soil & water samples for brownfield planning applications.

Process

Thanks to our expertise in building various types of controlled environments, our team was able to propose a solution meeting requirements of laboratory sample storage above a typical food-safe cold room without overextending into strict, clean facility standards.

The joint effort between Stancold and Adcock resulted in a value & specification-optimised design, precisely fulfilling the end-user’s needs.

Project Delivery

The installation team built the 105 & 30 m² spaces across two storeys in less than the estimated nine days, allowing our clients to complete the project ahead of schedule and demonstrating the advantage of partnering with experienced subcontractors.

Working with Stancold is a real pleasure and always results in a high-quality end product.

Adcock Refrigeration

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Divisional Wall for a Medical Equipment Manufacturer

Intersurgical

Background

Intersurgical, a global manufacturer of devices for respiratory care, reached out to Stancold to commission a divisional wall to separate production and storage areas.

Our client’s Facilities Manager recommended composite panels to their leadership team, who had never used such materials before. The essential factor was the non-disruptive installation method and Stancold’s guarantee for the facility to remain partially operational.

Process

Having conducted a site visit, Stancold proposed a non-fire-rated solution based on Kingspan Quadcore panels. The team recommended a set of rapid-rise doors to further limit dust from spreading around the critical parts of the warehouse.

Stancold’s sales & estimating teams delivered a satisfactory quotation, but the client’s yearly budget planning forced them to delay the project. Thanks to our commitment, we heard back from the client a year later.

Project Delivery

The build was completed in ten days, serving as an exemplary introduction to composite-panel-based construction to the client’s leadership team. Impressed by Stancold’s flexibility, efficiency, and the quality of the installation they decided to switch to such solutions for future projects.

We are extremely impressed with Stancold. The focus the team gave the project and their adaptability were brilliant. They will be my company of choice in the future.

Richard Howse, Facilities Manager

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Medical Research Cold Storage

Cancer Treatment Research

Background

CREST were invited by the project’s main contractor to tender for the turnkey cold room package that formed part of a new cancer research and treatment centre in central Manchester. Spanning ten storeys, the vast building required cold storage facilities for drugs and biocultures across four levels.

Process

The package required the supply and installation of three dual-compartment stores and four separate chillers and freezers within the building, which included the envelope build, refrigeration, flooring and lighting. Freezer temperatures needed to be at -20°C and chiller temperatures at +4°C.

CREST’s team were pivotal in providing guidance and support on the room specifications to both the contractor and the architect throughout the contract negotiation process.

Project Delivery

Due to the size of the building and the different working locations for our team, loading procedures to get materials and plant to the necessary levels were complex. A small goods lift was available to be booked for use by contractors on site, so required thorough planning from our team to ensure our works schedule was not impacted by loading delays.

Used to the challenges of large-scale contracts, the team demonstrated flexibility as the construction programme frequently changed, while working systematically alongside other trades on site to co-ordinate installation activities.

It was a privilege to be involved in this transformational research facility

Mark Kendrick, CREST Business Development Director

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N+1 Laboratory Cold Store

Cravencroft

Background

CREST were approached by South-East engineering contractor, Cravencroft, for the turnkey supply and installation of a cold store, as part of wider refurbishment works for a biotechnology services provider.

Process

Located in the sample storage area of a laboratory, the +4°C cold store specified N+1 redundancy capabilities as part of its operation, so required an experienced contractor to confidently undertake all elements of this package.

Satisfied with the level of detail provided from CREST during tender stage, Cravencroft appointed the team as the turnkey cold storage contractor for this project.

Project Delivery

CREST’s dedicated installation team successfully supplied and installed a cold store with an N+1 refrigeration system that met +4°C temperature specification. This included an auto changeover function to initiate the backup system if necessary.

The room itself was to be housed within a number of other traditional build rooms, generating a tight co-ordination programme for CREST’s first fix refrigeration works. Once complete, other trades were scheduled to carry out their responsibilities before our installation team could continue their build package.

This was another successful pharmaceutical cold store contract for CREST, utilising key technical expertise for the safe storage of high-value sample materials.

CREST demonstrated exemplary co-ordination all throughout the project.

Lee Duffield, CREST Construction Director

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Phased Food Production Facility Fit-Out

Minshall Construction

Background

Stancold’s food projects team were appointed as the internal fit-out contractor by leading industrial construction company, Minshall Construction, as part of a site redevelopment for an award-winning food ingredients supplier.

Process

Over a construction programme of three phases, Stancold were required to undertake the food-safe fit-out of a new-build extension, the installation of a blast freezer and reconfiguration works to an existing production area.

The team were able to advise on appropriate design changes to suit the services already in place and navigate complexities around a large bulkhead section to the first floor.

Project Delivery

Over the course of 18 months, Stancold collaborated closely with Minshall Construction to successfully complete the works in line with the scheduled programme, taking an approach that allowed the client to start operating in finished areas while others were still in progress.

Our package included the installation of both insulated and fire-rated composite panel systems, vision panels and doors to form high-risk and low-risk areas, airlocks and offices, all complete with a food-safe finish to fulfil the required safety standards and an aesthetically ‘clean’ fit-out throughout.

The team’s dedicated experience and understanding of constructing in live food manufacturing environments ensured that the delivery of this project met the end user’s expectations.

A food production facility transformed through this phased schedule of works

Sam Glover, Senior Contracts Manager

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Turnkey Pharmaceutical Cold Stores

Overbury

Background

CREST were approached by leading fit-out company, Overbury, as a specialist pharma cold storage contractor for one of the world’s leading biopharmaceutical innovators.

A pharmaceutical cold room was required on each floor of the end user’s two-storey research & development site in Stevenage, and came as part of wider ongoing refurbishment and modernisation works.

Process

CREST’s expertise in turnkey cold store construction for high-value pharmaceutical products confirmed that we were able to provide vital N+1 redundancy solutions and select a sustainable refrigerant option in line with the project specification.

Our team worked closely with Overbury during negotiations to ensure that the specification and build programme were in line with the end user’s requirements.

Project Delivery

Both turnkey cold room packages were designed and built to maintain an internal temperature requirement of +4°C. The rooms themselves utilised a panel system with FR30 rating, as per the contract’s specification.

Working on the first and second floor of the building meant materials were maneouvred via an internal freight lift and external hoist, a challenge that the team are well-versed in navigating from previous site experience.

Aligning our start on site with a rescheduled programme of works required pro-active coordination to ensure that the project was completed in a timely manner and to the end user’s satisfaction.

A successful turnkey contract for high-value pharma products

Steve Gunning, CREST Contracts Supervisor

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Acoustic Partition Walls

Hydac Technology

Background

Global electronics manufacturer, Hydac Technology, approached Stancold’s industrial partitioning team looking for a solution to segment the space in their recently acquired second warehouse.

Process

With a need to contain the sound of a large industrial area from an adjacent R&D function, Stancold’s versatility of partitioning solutions beyond fire safety meant that we could propose a suitable system for this application.

Through a site survey, our team were able to confirm that the proposed solution could be achieved using the building’s existing structural support and provided further consultation on door options for quick personnel and manual handling equipment access.

Project Delivery

Our expert team successfully carried out the design-and-build of the warehouse division wall, utilising Kingspan’s QuadCore panel system to achieve the required acoustic properties and span capabilities.

Two rapid rise doors were integrated into the wall and installed as part of the second phase of the programme delivery.

The problem-solving nature of both Stancold’s technical and site-based teams was the key driver in ensuring the smooth and efficient completion of this contract and a satisfied client.

This has demonstrated Stancold’s versatility in panel-build solutions

Sam Glover, Senior Contracts Manager

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Biomedical Holding Freezers

Pharmaceutical Manufacturer

Background

CREST previously completed the envelope fit-out of six cleanroom suites on this pharmaceutical manufacturing site and thanks to unrivalled knowledge of turnkey cold storage construction within the industry, were subsequently appointed for this requirement too.

Process

Situated in a modular warehouse on the ground floor of the site, our client required two industrial freezers for additional product storage. The specification required product to enter the room at -20°C and be maintained at this temperature.

CREST undertook the turnkey package, which included refrigeration, lighting, shelving and access ramps.

Project Delivery

CREST successfully coordinated the room build, commissioning of refrigeration and installation of internal shelving in line with our client’s specification.

The scope also included removable access ramps, person trapped alarms and door release functions, with racking designed around evaporators to optimise airflow.

Utilising knowledge of the different elements required for a turnkey solution like this ensured a seamless programme of works through CREST as the appointed contractor.

CREST has unrivalled expertise in turnkey pharma cold storage

Steve Gunning, CREST Contracts Supervisor

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Food Production Facility – Internal Fit-Out & Purpose-Built Extension

Speciality Food Manufacturer

Background

Stancold were involved in early-stage negotiations with a growing speciality food wholesaler, who were looking to expand and relocate their manufacturing facility within Birmingham.

Experienced project management contractor, Pentadel, took on the full turnkey package to transform and extend a tired existing building into a fit-for-purpose food manufacturing facility.

Process

Stancold were appointed to undertake the internal food-safe fit-out, alongside the internal and external cladding of a purpose-built extension, suited to product packaging and dispatch.

Our team worked collaboratively on the design and specification of this project to ensure that the end user’s requirements were met. Transferring specialist panel-build knowledge and skills into the external extension works allowed us to confidently add this element to our responsibilities.

The full specification included over 10 different areas, such as main production, a blast chiller, dry store and soy room.

Project Delivery

As part of a 9-month phased construction, which included coordinating with other contractors on the busy site, Stancold installed over 5500m² of food-safe insulated panels internally to form areas as per the end user’s specification, alongside a 60-minute sub-dividing firewall between the building and its new extension, another part of Stancold’s scope to meet fire safety building regulations.

The extension construction included all cladding, using goosewing grey trapezoidal panels from Kingspan’s roof system, and door canopy. These works also encompassed a one-hour fire-rated boundary wall, utilising a RockSpan composite core. With tight access to consider, panels were craned from a bank to the rear of the building, alongside narrow plant used throughout.

Internally, the fit-out incorporated bespoke window details to accommodate the building’s existing roof lights, as well as specialist flush windows, allowing free viewing into the main production area. The team constructed a bulkhead to neatly conceal air handling equipment and all existing steelwork was encased to maintain food safety excellence.

This was a large project that required timely planning, coordination and construction at every stage, where our team thrived in demonstrating such qualities.

You can take a tour around the facility here.

A project that demonstrated our commitment to the food industry

Sam Glover, Contracts Manager

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Bottle Wash & Production Rooms

Asian Cuisine

Background

Stancold worked with our client’s appointed consultant to supply and install two new food-safe rooms as part of their main production area within their South Wales facility.

The client specialises in the manufacturing of Asian sauces and marinades, aswell as new product development within this sector.

Process

Our dedicated food projects team worked closely with our client and our supply chain to navigate through unforeseen market-led material challenges. Our long-standing relationships with suppliers were indispensable in ensuring that the contract’s programme of works could be successfully achieved.

Project Delivery

Stancold’s in-house installation team utilised a PIR panel system with a food-safe finish to construct a bottle wash and wash room, accompanied by doors and vision panels.

Our working area was temporarily cordened off from our client’s live manufacturing environment. The team’s experience of working in this way, across many projects to date, was vital in keeping to schedule and with minimal disruption to our client’s continued operations.

This was another successful contract for our dedicated team to support growth and expansion within the food & drink industry.

Live environments are no problem

Sam Glover, Contracts Manager

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Food-safe partitions for new production rooms

Chilled & Ambient Pharmaceutical Storage

Pharmaceutical Distribution

Background

CREST were approached by our client to deliver temperature-controlled pharmaceutical storage within their existing warehouse. Our team were able to offer a turnkey package and assumed responsibility for the panelling, refrigeration, lighting, doors and door protection.

These environments were to be utilised for the storage of temperature-critical pharmaceutical products and aid our client’s compliance for good distribution practice (GDP).

Process

Understanding the bespoke nature of critical environment builds such as this, the team completed multiple site surveys to gain a better understanding of the site conditions and to confirm minor design changes.

Project Delivery

Our specialist installation team successfully supplied and installed the pharmaceutical chiller, meeting the 2-8°C temperature specification, with adjoining ambient area (15-25°C), and utilised Kingspan’s QuadCore panel system to do so effectively. Situated underneath a mezzanine floor, the team had to carefully plan the coordination of refrigeration and HVAC equipment to accommodate.

Whilst there was good access to the site, it remained a live environment, so daily coordination meetings were arranged to minimise disruption to day-to-day operations.

However, the team are well-versed in overcoming such intricacies and worked hard to successfully deliver the project according to our client’s programme of works.

A build that demonstrates our pharma expertise

Lee Duffield, Contracts Manager

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Pharmaceutical distribution chiller build

Food-Safe Cold Storage Facility For Fresh Produce

Riverford Organic

Background

As part of their exciting expansion plans, our client, Riverford Organic, called upon us again to assist in the construction of a chiller facility within their new distribution hub in central London.

Process

As their preferred supplier for all food-safe panelling works across their sites, Stancold worked closely with their project manager and the appointed refrigeration contractor to ensure that the room specification was met for the storage of fresh produce, and construction timescales were agreed.

Project Delivery

Our team successfully installed the 120-pallet cold storage facility, measuring 16m x 12.5m, alongside 3 doors – a hinged chiller door, fire exit door and an automatic sliding chiller door.

Thanks to its superior insulating properties and white food-safe laminate finish, Kingspan’s QuadCore panel system was the most suitable option for these works, while the automatic sliding chiller door was chosen for access efficiency and convenience.

This was another successful project for a valued returning client that highlights our unrivalled understanding and knowledge of food-safe construction for more than 75 years.

It’s a pleasure to assist Riverford Organic as they continue to grow

Sam Glover, Senior Contracts Manager

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Cleanroom Extension Fit-Out With Firewalls

Pharmaceutical Manufacturer

Background

Working under on-site project management contractor, Specific Environments Ltd, who were responsible for developing a full turnkey cleanroom solution, the Stancold’s Clean Room Envelope Specialist Team were tasked in undertaking the cleanroom envelope fit-out within this pharmaceutical manufacturer’s new extension.

Process

The project required an intricate scope of works to best accommodate the end user’s accelerated manufacturing plans and utilisation of redundant space, in and around complex steel structures.

Our team’s consultative nature allowed us to explore a number of panel system combinations with the end user, taking into account the need for fire protection and their budget.

The final package required the integration of three different panel systems to ensure that the specification was successfully achieved.

Project Delivery

Stancold’s responsibilities included the construction of all cleanroom walls, walk-on ceilings, doors, vision panels and 60-minute firewalls, amounting to nearly 8000m² of works.

The team combined Puracore’s Aluminium Honeycomb, Kingspan Versatile and Eurobond Firemaster panel systems to complete the works, utilising each system’s advantages to match the overall complexity. A key strength within our offering includes the ability to accurately colour match all systems, which provided a perfectly white finish throughout this facility.

Two installation teams worked in unison to complete the construction of the cleanrooms and firewalls simultaneously, so the project was successfully finished within the assigned schedule of 15 weeks.

A complex build that exhibits our specialist knowledge

Lee Duffield, Senior Contracts Manager

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Temperature-Controlled Biopharmaceutical Production Facilities

Area

Background

Commercial workplace specialists, Area, part of the wider Fourfront Group, required a contractor to undertake the design and build of four temperature-controlled facilities within a newly built warehouse in Hampshire.

The warehouse’s new tenant manufactures key machinery systems for the life sciences and biopharmaceutical sectors, and this area will house the final testing phase of their production line.

Process

CREST worked closely with Area’s team and our recommended refrigeration partner to find a system that would accommodate the required temperature range of +2°C to +26°C.

Where the facility operates a large robotic crane, CREST also carefully considered different door options and proposed a suitable solution as part of our package.

Project Delivery

CREST delivered four chilled rooms and accompanying doors to facilitate this project’s specification. Kingspan’s Quadcore panel system was the best suited option for this application, thanks to its reliable insulating properties, and space-saving roller-shutter doors integrated within the design to accommodate the warehouse’s crane.

Two areas were built beneath an 8m-high mezzanine floor, so the team created an efficient workaround plan to install ceilings safely, where access was particularly tight. Manoeuvrability of wall panels and use of lifting equipment in this space were also carefully monitored, especially when coupled with other craning machinery within the main warehouse.

CREST successfully completed the works within 3 weeks, demonstrating strong expertise and faultless construction technique for this application.

Our team successfully achieved the intricate specification

Sam Glover, Senior Contracts Manager

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Beverage Processing Area Upgrade, Kegworth

Drinks Producer

Background

Stancold have worked with this bottled drinks producer for many years on their Somerset site, and thanks to a number of successful projects there, we were recommended to undertake works within their Kegworth facility.

Process

As part of the required upgrade works, Stancold were asked to install full-height food-safe partitions to form a process area, ingredients room, handwash station and cold store. The specification also included an airlock between existing storage space and the new processing area. Our team were able to recommend materials and ancillaries that best suited the developing design, while planning a schedule that co-ordinated with the client’s dedicated shutdown period.

Solution

Stancold’s installation team worked hard on site to complete over 1700m² of partitioning works using the Kingspan Quadcore panel system, complete with a food-safe laminate finish. This project included the integration of 4 rapid rise doors and 3 personnel doors, along with 2 large vision panels for free viewing between areas. All exposed original steelwork was encased with white food-safe cladding to create an aesthetically-pleasing finish and match the surrounding fit-out. Our team demonstrated reliability and delivered vital product expertise to successfully achieve the desired design specification for these works.

The whole team that installed the Kingspan walling, performed professionally throughout the project

Project Engineer, Drinks Producer

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Holding Freezer For Food Wholesale, Essex

Time Wholesale UK

Background

Our client, Time Wholesale UK, required an additional temperature-controlled facility for the storage of ice products.

Process

Stancold worked with our trusted refrigeration partner to provide a solution that was able to meet the temperature requirements of -22°c, accommodating a facility design that suited the available space within the wholesale warehouse.

This included installing the condenser unit to the rear of the room so that the entire facility remained completely self-contained.

Solution

The team constructed a facility measuring 6m x 6m x 2.75m to suit the client’s specification. Kingspan’s Quadcore system, of 100mm panel thickness, was utilised for the build thanks to its superior insulating properties. Panels were complete with a food-safe finish to maintain high-quality hygiene standards.

Aluminium treadplate protection was added to all internal walls in order to prevent damage from forklifts and pallet trucks.

A sliding freezer door, strip curtains and an insulated concrete floor were also installed as part of the project specification, where the timing and co-ordination of each element was key to ensure a successful build and a satisfied client.

Another project successfully completed through our team's systematic approach

Sam Glover, Contracts Manager

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Food-Safe Cheese Production Extension, Bath

Bath Soft Cheese

Background

After working successfully with Bath Soft Cheese on their new cheese factory around 5 years ago, Stancold were delighted to be approached by the cheesemaker once again as part of their new venture on site.

Process

To expand their capabilities, Bath Soft Cheese required a food-safe fit-out within their recently built extension, therefore creating new space for maturation and blue cheese production.

Our team worked consultatively with the client and their architect to assist with the project’s design specification so that it met their operational requirements. The site’s locality to our main office allowed for our project management team to easily complete site surveys and design meetings as required.

Solution

Stancold’s team installed approximately 600m² of Kingspan Quadcore panelling to form six new areas within the extension. The design also incorporated Mineral Fibre panelling to provide vital passive fire protection as per Building Control regulations.

The client’s mezzanine floor was neatly capped and cladded around to ensure an aesthetically-pleasing finish. This was accompanied by 8 new personnel and sliding doors, alongside the re-installation of two of the client’s existing doors.

This was a well-managed project throughout, particularly where COVID safety measures were in place, leading to an efficient install and a satisfied client.

Our team demonstrated efficiency and, of course, safety on this project

Sam Glover, Project Manager

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New hygienic rooms for cheese production

White wall panelling for cheese production extension

Hygienic areas for cheese and dairy businesses

Hygienic Production Areas for Essential PPE Manufacturer, Leicestershire

Pal International

Background

Manufacturer of cleaning & PPE products, Pal International, approached Stancold in the midst of the COVID-19 pandemic. Due to the Government advice imposed across the UK, they saw their product range in significant demand. To facilitate this sudden increase, they required additional space to house a new production line.

Process

Stancold reacted quickly across every aspect of this project. To ensure the client made effective use of their vacant space, we undertook a consultative approach and value-engineered a design that utilised existing walls.

Where the project needed to be on site within a matter of weeks, our long-standing relationships with manufacturers and suppliers were vital in ensuring a rapid turnaround to begin construction.

Solution

The project’s final design involved 6 new hygienic areas, all at differing heights, with openings to accommodate product equipment, alongside the installation of personnel doors.

Kingspan’s Quadcore panel system was best suited for this build, due to its high-quality hygienic finish. Ongoing circumstances meant that health & safety was a key consideration while working on site, where the team adhered to strict social distancing measures and precautionary checks as advised by Pal International.

Stancold’s ability to mobilise quickly and work efficiently during such unprecedented times ensures that our client’s tight schedule was met and their operations unaffected.

Demonstrating efficiency and safety were key in this project.

Sam Glover, Stancold Contracts Manager

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Hygienic Rooms Built For New Production Lines

Turnkey Frozen & Chilled Storage Package, Kent

Albion Fine Foods

Background

Due to increased demand for their products, Albion Fine Foods, a foodservice provider serving the South East, required additional storage as part of their first phase of expansion plans.

Process

Within the client’s newly acquired warehouse, Stancold were able to offer a full turnkey design & build solution to suit their needs. This included the co-ordination and installation of food-safe panelling, doors, refrigeration, racking, flooring and electrical connections.

We worked alongside our client’s nominated refrigeration contractor throughout the project, where pre-construction meetings between the three parties were essential to discuss design details and provide guidance on the finer elements of the build.

Solution

Stancold worked efficiently and professionally using the Kingspan Quadcore panel system on this project.

Complete with a food-safe finish, the large freezer was constructed using 150mm thick panels, while the chiller utilised panels of 100mm thickness, covering a total area of over 780m². Both facilities were installed with specialist Kingspan sliding doors.

The team co-ordinated the installation of the freezer’s concrete flooring, heavy-duty racking for 280 pallets and a refrigeration system to allow the unit to reach -18°c.

This project was completed in just 6 weeks, leaving our satisfied client with fully operational facilities ready to be filled with product.

A total pleasure working with you, can’t speak highly enough of your whole team

Toby Raphael, Albion Fine Foods

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Butchery Production Facility Extension, Bristol

John Sheppard Butchers

Background

John Sheppard Butchers, a fresh meat supplier of over 60 years, constructed an extension using vacant space between their two existing buildings on site in Bristol. They required an additional three chillers within it for storage of their products.

Process

Using our decades of experience within the food & drink industry, Stancold worked closely with the appointed architect to carefully develop the design of chilled storage units. Through thorough site surveys, we were able to provide advice on the most suitable materials for the build.

Our work followed the installation of a resin floor by others and concluded all the construction elements of the new-build extension.

Solution

Stancold successfully supplied and installed 685m² of Kingspan Quadcore insulated panels to form three food-safe chill stores. This was accompanied by hinged and sliding chiller doors, a single hinged personnel door and a one-hour fire-rated personnel door.

In order to separate the office space above from the new production area, the team also installed a one-hour fire-rated ceiling using Eurobond Mineral Fibre 100mm panels.

This was yet another project where Stancold demonstrated superior technical and industry knowledge to create a custom-fitted hygienic facility.

A great local project demonstrating our expertise in food-safe systems

Sam Glover, Stancold Contracts Manager

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4,000m² Fill Finish Cleanroom Facility For Vaccine Production, Liverpool

Boulting Environmental Services

Background

After working together previously, respected specialist cleanroom contractor, Boulting Environmental Services, invited Stancold to tender for the installation of 4000m² of cleanroom panels in their latest pharmaceuticals project.

Process

This project required Stancold’s expertise and experience within pharmaceutical cleanrooms to install Aluminium Honeycomb and insulated panels, forming a new Fill Finish facility. The end user, a worldwide manufacturer and supplier of vaccines, were moving this area of operations in-house to their manufacturing site in Liverpool.

Solution

Stancold installed both Kingspan QuadCore and Puracore Aluminium Honeycomb panels to successfully complete the fit-out. Covering two floors of the facility, the cleanrooms were constructed simultaneously by two separate Stancold teams, achieving a semi-flush environment within the lower level and a fully flush, high-end pharmaceutical cleanroom on the upper level. The build also included the integration of flush single hinged, double hinged and personnel doors, as well as double glazed flush vision panels. Three cold storage units were also required as part of our installation package.

Stancold’s strong technical ability in installing controlled environments was fully utilised throughout this 20-week project on site.

With a difficult design to follow and a tight programme, it was an excellent install.

Steve Daly, Boulting Environmental Services

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Pharmaceutical Cold Storage, Liverpool

Boulting Environmental Services

Background

After working together previously, respected specialist cleanroom contractor, Boulting Environmental Services, invited Stancold to tender for the cold storage works in their latest pharmaceuticals project.

Process

Alongside over 4000m² of composite cleanroom panels, the large project required Stancold’s expertise and experience to integrate three pharmaceutical cold stores, including refrigeration, within the new Fill Finish facility. The end user, a worldwide manufacturer and supplier of vaccines, required facilities to house their products and materials under controlled temperature conditions.

Solution

Stancold installed Kingspan panels of 100mm thickness to create the three cold stores measuring 18.5m x 7.8m, 10m x 3.7m and 10.3m x 6.5m, and were integrated with insulated rapid roller doors, fire escape doors and insulated sliding doors for efficient product and personnel access. Two cold stores on the ground floor required a ‘controlled not classified’ status while the third, located on the first floor, needed to achieve EU GMP Grade D standard. The units have been constructed to achieve a temperature range of +2°C to +8°C in order to meet the requirements of the product.

Like in many pharmaceutical cleanrooms where the value of the product being stored is so high, all cold stores required 100% backup, so if any equipment fails, the rooms will still remain fully operational.

This project demonstrated Stancold’s full capabilities in installing pharmaceutical cold storage for vaccinations, using our extensive technical knowledge to meet the needs of our clients.

With a difficult design to follow, it was an excellent install.

Steve Daly, Boulting Environmental Services

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Food-Safe Chiller for Online Grocery Distribution Centre, London

Glencar Construction

Background

Stancold have a long-standing relationship with both Glencar Construction and the end user, Ocado, where we have previously supplied and installed cold storage facilities on site.

Process

Working with Glencar throughout the tendering process, Stancold were able to produce detailed design plans to carry out the installation of a new cold storage unit for Ocado’s home delivery service.

Solution

Stancold installed a hygienic chilled storage facility with Kingspan Quadcore panels, using 150mm for ceiling construction and 125mm for the food-safe walls.

A number of hinged and auto sliding chiller doors were also integrated for quick access into and out of the unit.

Stancold’s strong technical expertise and experience in installing temperature-controlled food environments saw this project completed on time.

A project that was delivered on time and to a satisfied customer

Sam Glover, Stancold Contracts Manager

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Panel for online food distribution centre

Temperature-Controlled Marshalling Area for Large Food Distribution Hub

ISS Property

Background

Following a client recommendation, Stancold worked with commercial property specialists, ISS Property, to create a large chilled marshalling area in a food distribution hub in Coventry. With the end user recently taking over the site, they were looking to make modifications to better suit their operations.

Process

The marshalling area allows products to be inspected and sorted after being picked from the chilled warehouse, before being loaded onto delivery vehicles. Therefore, it was important to explore different designs for the space, where Stancold’s strong technical knowledge was fully utilised to implement a solution that optimised the end user’s needs.

Solution

Stancold’s in-house installation team constructed the chilled marshalling area using 3760m² of Kingspan Quadcore panels. An intricate ceiling design was also completed to allow for the installation of a fire suppression sprinkler system. The build included the integration of the client’s existing sectional doors as well as the installation of new rapid-rise freezer and chiller doors and vision panels.

The project was completed within 6 weeks and with a quick timeframe from initial enquiry through to the project handover, Stancold’s 75 years of experience in food & drink was valuable in achieving a high-quality solution.

Great work from the team across this successful 6-week installation

Lee Duffield, Stancold Project Manager

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Hygienic panels for food distribution hub

Fully Flush ISO 8 Cleanroom Suite For Probiotics Production, Somerset

NGS Cleanrooms

Background

Stancold have a long-standing relationship with cleanroom specialists, NGS Cleanrooms, who undertook the design and construction of an ISO 8 cleanroom suite for their client, a probiotics manufacturer in Somerset.

Process

Stancold worked closely with NGS Cleanrooms and Puracore, producing detailed design plans for the large bespoke cleanroom build.

Solution

The project required the installation of 1250m² of FM Approved Puracore Aluminium Honeycomb Cored panels, fully flush vision panels and rapid roller shutter doors to form 28 processing rooms. Stancold also supplied and installed an integrated one-hour firewall, using Kingspan Mineral Fibre Cored 100mm panels. This included the fitting of double ‘hold open’ fire-rated personnel doors and all firestopping to achieve maximum fire integrity. Stancold were responsible for the suite’s cold storage facility, constructed using Kingspan Quadcore panels and completed with a white food-safe finish to match the rest of the Grade D cleanroom suite. There were a number of intricate and complex details to the project, such as the seamless integration of motion-sensor service points for doors and air return columns. Stancold’s specialist expertise and strong cleanroom experience enabled the 6-week bespoke project to be completed successfully.

Stancold's expertise in this field really shone on this project.

Lee Duffield, Stancold Project Manager

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Cleanroom installation for pharmaceuticals

Fully flush vision panels for cleanrooms

Cleanroom Partitions For Medical Technology Provider, Devon

Haldons Construction

Background

After successfully working with Haldons Construction Consultants at a medical technology company in 2017, Stancold were asked to complete a second cleanroom partitioning project on the same site.

Process

As this was a complex project and was to be conducted in a live environment, the Stancold team attended numerous site visits with Haldons and the end client to discuss finer details of the installation process. Working closely with both parties provided the necessary support in the pre-construction stage of the project.

Solution

As per the client’s requirements, Stancold dismantled and removed the temporary walls in place and then erected 500m² of new cleanroom partitions using Kingspan Quadcore 80mm panels integrating a hinged personnel access door.

Using our strong expertise of working in a live environment, appropriate measures were implemented to ensure no construction debris left the area outside of the temporary screens and panels were cut away from the construction area, allowing the client’s working operations to continue as normal.

Communication from Stancold is always brilliant

Simon Buchanan, Haldons Construction

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Cleanroom partitions with hinged personnel door

Cleanroom 80mm partitioning on site at medical device manufacturers

Cleanroom partitions for medical device manufacturers

10,000m² Production & Storage Facility For Food-To-Go Manufacturer, London

Food-To-Go Manufacturer

Background

Due to continued business growth, this food-to-go manufacturer needed to expand their production facility.

Process

For this complex scheme, we had to consider the different temperatures for chillers, freezers and packing facilities along with fire-rated areas. The plan included a range of facilities; ingredient chillers, product preparation rooms, temperature-controlled packing areas, low-temperature storage and marshalling areas, alongside the installation of 58 doors.

Solution

To suit the requirements of each room, a range of different panel thicknesses were used across the project, including a 175mm firewall. Due to its large-scale nature, a project re-design was required during installation to include adaptations to work around steel walkways in the ceiling. The complexity of this project really displayed the team’s technical capabilities.

A large-scale complex project delivered exceptionally by the team

Lee Duffield, Project Manager, Stancold

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£1.5m Shellfish Processing Facility, Lancashire

AM Seafoods

Background

AM Seafoods needed to double their production capacity with a new purpose-built facility, grant aided by the Marine Management Organisation and European Fisheries Fund.

Process

The final design incorporates a low care raw goods reception chiller, high care cooking area with steam production, ventilation, various production lines, chilling and packing areas, blast freezers and a holding freezer, as well as staff welfare areas and all of the associated facilities to support this.

Solution

As project managers, we co-ordinated the project from sourcing equipment to modifying plans and associated specifications. This required incorporating existing foundations and AM Seafoods’ specially designed complex production facilities as well as staff areas with changing facilities, canteen, offices and ancillary fit-out.

The new facility is designed so that the company has the space to keep growing in a sustainable way.

I think what I appreciated most, was feeling that nothing was too much trouble, and no problem insurmountable. The new facility will allow us to deliver a first class product for many years to come.

Mark Merrick, Director of AM Seafoods

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Food safe panels for shellfish processing facility

Hygienic Partitioning for Food Factory Expansion, Yorkshire

Pro Pak

Background

In order to produce a new product range for a national supermarket, the Pro Pak factory needed a full renovation and Stancold had been recommended by one of their suppliers to carry out the works.

Approach

Our team carried out a full survey of the prospective area within their existing ready meal facility, offering budget pricing and feasibility assistance in the initial stages. As the scheme developed, we created a programme of works and carried out value engineering assistance to ensure the client received a fit-for-purpose scheme that met their tight budget.

Solution

We created the high care rooms and lined walls in the existing building with Kingspan KS1100 Quadcore panels and removed the current kitchen and changing area walls as well as carrying out general modifications to ensure that site met the stringent hygiene requirements demanded by the client. The works were carried out on time and to budget to the complete satisfaction of our client.

Stancold installers were excellent. We’re very likely to use you again for future work.

Steve Caulton, Pro Pak

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Hygienic panels for food production facility

Stancold team installing hygienic panels

Chilled Loading Bay for Food Distributor, Dorset

Hunts Foods

Background

As a thriving foodservice business, our client needed to increase their chilled capacity, loading capacity and marshalling areas to cope with peak demands. As Stancold had worked with Hunts in the past, we were delighted to work with them to deliver a solution.

Development

Stancold visited site on several occasions to understand the restrictions and also developed a design, budget and build programme with our client’s on-site team. After several revisions and amendments, a final scheme was settled and budget fixed.

Solution

Kingspan KS1100 CS Quadcore wall panels enclosed the existing exposed canopy and provided valuable insulation as well as protection from the elements, which were cut to suit the variety of existing floor levels. During the summer, the heat underneath the canopy was putting an extra burden on the low-temperature coldstore. Our solution of creating a chilled loading bay not only added capacity but enabled the cold store to work more efficiently.

You did a professional job, we’re very likely to use you again

Mike Douche, Hunts Foods

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Loading bay doors in chilled area of food facility

Chilled loading bay installed at Dorset food distributor

Insulated chiller door for food facility

Build of Multiple Rooms, Chiller & Freezer Storage, Enfield

Japanese Food Distributor

Background

The new client required our expertise to specify, design and construct a frozen and chilled storage solution, as well as a distribution warehouse for Europe’s biggest importer and developer of Japanese food as they acquired new premises in Enfield.

Requirement

Japanese food has grown in popularity so the company needed to expand and adapt their facility to enable them to better serve their UK and European customers.

Solution

The team constructed a series of rooms for storage and distribution including a 44.26m x 15.07m x 10.12m high freezer. To enable easy access, we installed a 3m wide x 4m high rapid rise door. Due to the high value and storage requirements of Sake, a separate chiller was created alongside the vegetable chiller for fresh produce. We also installed a dock chiller to keep the products at the correct temperature.

It was an exciting project that required different stages of storage and distribution.

Sam Glover, Contracts Manager, Stancold

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Installing panels for chiller and freezer facilities

Hygienic panels for alcohol beverage chiller

Rapid rise doors for easy access to food freezer facility

Workshop & Partition Walls, Tea Supplier, Hampshire

Brammer

Background

Having worked closely with the engineering manager at Twinings in his previous role, we were very pleased when he got in touch directly when they needed partition walling to separate their production facility and a new workshop.

Requirement

A new workshop area for maintenance (7.60m x 4.84m x 3.50m high) and a series of five partition walls. The workshop area was to have two vision panels and five hinged personnel doors. A roller shutter door was installed in the partition wall leading through to the factory for ease of access.

Solution

The challenge with the installation of the workshop and the partition walls was that the team had to work around the live factory. This was no problem thanks to a dedicated project management and an experienced installer team.

“Great installation and great communication [with the project manager], nothing you could improve on!”

John Gibbons, Brammer

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Firesafe panels for workshop partition walls

Freezer, Chiller & Distribution Centre

Newberry International

Background

As a supplier and distributor, Newberry International Produce were looking to build a factory in Gloucestershire to make UK distribution easier.

Requirement

The full turnkey works with 1099m² of panelling. A coldstore freezer with mobile racking to store stock and three chiller rooms for preparation of the client’s produce. Alongside this was a packing room and loading dock with direct access.

Solution

Stancold organised the complete build from ground works, building the freezer and chiller rooms, refrigeration, flooring, lighting and floor slabs with appropriate ramps. We also designed and built a solution to allow a loading bay direct from outside the building into the freezer, a difference in temperature up to 60 degrees.

Co-ordinating multiple trades and the design of the mobile racking were the biggest challenges on this project. Fortunately, the expertise of our contractors and flexibility of the client meant the project went seamlessly.

Bob Bryant, Project Manager, Stancold

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Hygienic composite panels for food distribution centre

Sliding chiller doors in cold storage installation project

Inside the hygienic cold storage unit for food production

Doors and panels at food distribution centre

ISO 7 Cleanroom

Monmouth Scientific

Background

Our client was contacted by a leading manufacturer of conductor and fibre optic cables for the aerospace and defence industries who had the requirement for a new ISO 7 cleanroom.

Process

A 90m² footprint self-supporting cleanroom, complete with an airlock compartment, was required. Our client also required the design to perform with multiple ceiling openings to accommodate the lighting and HEPA filters, all built to a tight deadline and in a working laboratory environment.

Solution

Stancold provided Kingspan insulated wall and ceiling panels, expertly fitted with doors and windows and designed to take the ceiling loads. The project required close project management due to the restrictive programme and site conditions; access was tight and limited. Our experienced team once again rose to the challenge leading to another satisfied client.

Watch the project’s timelapse video here.

Excellent, a job really well done.

Dave Court, Monmouth Scientific

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ISO 7 cleanroom with insulated wall and ceiling panels

ISO 7 cleanroom with insulated wall panels

Cordial Production Area

Belvoir Fruit Farms

Background

In 2014 due to increased demands for their products, award-winning cordial makers, Belvoir Fruit Farms, have invested into relocating their factory from Bentham to Bottesford.

Requirement

Supply and installation of approx. 5000m² insulated white food-safe wall and ceiling panels to form a new production area of approx. 2000m² including fire-rated partition walls, a chiller, hygienic and temperature controlled production and packing areas.

Solution

The Stancold team have reconfigured a number of existing buildings to create the right conditions and enable the customer to increase their production capacity.

Installation was completed on time and on budget.

Frank Fitzgibbons

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temperature controlled production in cordial factory

fire rated partition walls, chiller, hygienic and temperature controlled production

hygienic and temperature controlled production

Freezer Extension

Upton Farm Frozen Foods

Background

Upton Farm Frozen Foods are an established wholesaler based in West Wales providing frozen and fresh local produce for the catering industry.

Requirement

Due to the increased demand for their products, the customer had appointed Stancold to double their existing frozen capacity. Stancold have supplied and installed Kingspan PIR panels with ancillaries and floors to ensure maximum thermal insulation.

Solution

Careful phasing of the works were paramount to the success of this project. With an existing ceiling to support and concrete floor to match, a cautious and timely approach was essential. Handing over the new freezer space without delay was mission critical. Fortunately, Stancold have considerable experience in this type of work which meant that we could iron out most of the potential issues in the design stage leading to yet another happy customer.

The installers were very professional and polite. I was very pleased with the end product. The job went brilliantly.

Richard Francis

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