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

Location	Wales
Building Use	Food Ingredients Manufacturing
Panel Core	QuadCore; Mineral Fibre
Panel Supplier	Kingspan; Eurobond
Panel Thickness	100mm
Panel Requirements	1710m²
Services	Phased Construction Programme
	Design Flexibility
	Live Production Environment

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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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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60-Minute Fire-Rated Access Corridor

Fuselek

Background

Stancold were approached by interior fit-out contractor, Fuselek, to complete the design and build of a fire-rated corridor, as part of larger works for a food manufacturing facility less than 5 miles from Stancold’s head office in Bristol.

Process

Designed to provide access to three newly formed labs, the corridor required a one-hour fire-rating, with a mezzanine floor constructed above, to follow on after our works. On Stancold’s doorstep, a site visit confirmed access points and the feasibility of the proposed installation method. The team’s trusted expertise of composite panel systems for fire-rated applications made sure that each of the design, specification and build elements could work together to achieve the required solution.

Project Delivery

Stancold’s industrial partitioning team utilised Eurobond’s Firemaster composite panel system, in 150mm thickness, to construct the fire-rated walls and ceiling, thus achieving the FR60 certification. Our LPS-approved installers completed the contract in just one week, enabling the next phase of site works to continue smoothly.

Stancold's fire-rated expertise has been demonstrated once again

Rob White, Contracts Manager

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Eurobond Firemaster corridor construction

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

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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Independent Insulated Panel Inspection & Report Package

Dairy Producer

Background

As food safety requirements have been significantly overhauled and continue to change within the industry, insurers and trade bodies require further evidence on the products used within food manufacturing facilities.

On their insurer’s request, our client required Stancold to undertake an inspection of the panel systems used within their production facility, and produce a core sample box with a corresponding report identifying their make-up.

Process

Once the required inspection areas were highlighted, Stancold’s team arranged a time to visit site, armed with the correct tools to extract panel core samples and neatly fill and reseal.

Project Delivery

The experienced team took over ten samples across the facility, always surveying in inconspicuous areas within both walls and ceilings to maintain tidiness. This process showed that polystyrene-cored panel systems and PIR panels were present and that there were some areas of damage and delamination.

In areas where access wasn’t feasible on the day, the experienced team were able to make informed assumptions about the panel insulation material and clearly indicated this on the report submitted to our client.

Through utilising expertise and industry experience of over 75 years, Stancold were able to reliably offer an independent service to assist with this essential insurance validation process.

We’re pleased to be able to utilise our industry knowledge

Sarah Gore-Booth, Stancold Project Coordinator

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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

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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Food-Safe Fit-Out in Production Extension for National Food Manufacturer, Slough

National Food Manufacturer

Background

Following a competitive tender process, Stancold won the work to complete the entire internal food-safe fit-out for a new production area extension spanning two floors, undertaken by national contractor, Walker Construction.

Process

The end user, a household name in food manufacturing, specified non-combustibility as a key factor within the construction. To meet their requirements, Stancold were able to offer white food-safe panelling with a Mineral Fibre core, and worked consultatively with Walker Construction and the end user to accommodate changing design specifications before starting on site.

Solution

Stancold installed over 4200m² of Mineral Fibre core panelling with a food-safe finish, to form a number of new areas within the vast production warehouse space. This included goods-in areas, pallet stores, stairwell enclosures between floors, hygienic corridors and plant rooms.

Stancold were also responsible for the installation of all single and double fire exit doors, as well as 60-minute fire-rated doors where required; approximately 40 in total.

The team took care of the intricate construction details around the existing steelwork, carefully matching up panel joints for an aesthetically-pleasing finish throughout.

Our attention-to-detail and flexibility on site, working with and around other contractors, were key elements in ensuring that the build was a success.

A large-scale fit-out project delivered exceptionally by the Stancold team

James Hoy, Contracts Manager

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Meat Conveyor Facilities, Bristol

Meat Producer

Background

Stancold have been working with the end user, a successful meat producer, for 5 years, and have a strong relationship with the local engineering firm overseeing all works on site in Bristol.

Process

As part of the end user’s ongoing facility upgrade works, the end user required a new meat conveyor area within their existing production hall.

Stancold were entrusted with this project, undertaking the installation out-of-hours to minimise disruption to day-to-day operations.

Solution

Our in-house installation team constructed two conveyor rooms using white food-safe full-height panels, installed to the existing ceiling. Sliding doors and vision panels were seamlessly integrated into the facility.

Stancold also created openings within the partitioning to allow for the client’s new conveyor equipment to pass through, neatly capping off where required so insulation is not exposed.

Our strong workmanship and excellent technical product knowledge enabled this project to run smoothly and flexibly.

Another efficient food-safe build for a valued client

Sam Glover, Project Manager

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Hygienic Production Area Fit-Out for Foodservice Relocation, Chichester

Parkers Foodservice Ltd

Background

To be able to expand their service offering across pubs, schools and hotels, family-run wholesaler Parkers Foodservice entrusted Stancold to assist in their relocation to larger premises in Chichester.

Process

The new building required a production area fit-out, which included two freezers, three chillers and a preparation area. On the site survey, Stancold were able to offer advice on suitability for their needs and adapt the design accordingly.

Due to the existing structure of the premises and a mezzanine to work beneath, attention-to-detail was key throughout the design stages to accommodate expected intricacies during the install.

Solution

Stancold utilised Kingspan’s Quadcore hygienic panelling system to construct five temperature-controlled areas, two freezers and three chillers, alongside a prep area within the vacant space. The was accompanied by a number of sliding freezer and chiller doors to complete the fit-out.

The team carefully cladded all existing steel columns, working efficiently and flexibly as several design changes were made over the course of the installation.

The project was successfully completed in under three weeks, to the client’s specification and level of satisfaction.

A detailed installation successfully achieved by the team

Sam Glover, Project Manager

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Hygienic Automated Sorting Warehouse, Wales

Puffin Produce Ltd

Background

Following the continued growth of the business over recent years, Puffin Produce Ltd, a grower and supplier of fruit and vegetables, planned to introduce an automated sorting warehouse on their Haverfordwest site to improve efficiency.

Process

Stancold began discussions with Puffin Produce Ltd regarding the food-safe partitioning required to house the new automated sorting equipment on site.

We worked consultatively with the appointed architect during planning to design and then propose a detailed scheme of works, which consisted of allowances for intricate details within the project. This included a horizontal panel installation due to the 19m ceiling height and creation of penetrations for the equipment’s cabling.

Solution

Stancold installed four hygienic partitions in the warehouse, using Kingspan Quadcore 100mm panels to achieve a food-safe finish. Given the 19m ceiling height, the panels were installed horizontally between the existing framework, as a vertical build would not have been possible.

The team also created a series of penetrations within the partitions to allow for the cabling of the new equipment to run through, an element of the build that required planning and accuracy. The hygienic space was integrated with a number of personnel doors and a vision panel, expertly installed by the team to complete the works on site.

Our continued flexibility in adhering to both the site and customer requirements throughout this project was key in ensuring a successful completion with a satisfied customer.

An intricate design and build that we completed successfully

Sam Glover, Project Manager

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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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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

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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Hygienic & Fire-Rated Panels for Seafood Processing Facility, London

Seafood and Eat It!

Background

Stancold was selected for this project because of our experience in the seafood industry, understanding of the project requirements and good communication with the project management team.

Process

We worked with Seafood and Eat It as their design for the proposed mezzanine floor developed, ensuring we still met all their requirements. We installed a series of rooms to create a new processing facility for crab meat, which included freezer, chill and refrigeration rooms and a blast chiller, as well as an office.

Solution

To ensure protection for the mezzanine floor, we installed an independently suspended fire-rated ceiling which was tightly fitted to the existing ceiling. We continued to adapt to the client’s wishes as the project developed, installing the 2.00m x 2.00m x 3.40m high chiller upstairs where it will be used for testing. Stancold used their technical knowledge and product expertise to create this suite of rooms for this processing facility, using both Kingspan and Eurobond panels. The installation was finished on time.

A great example of our flexibility to changing plans and design

Sam Glover, Contracts Manager, Stancold

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Hygienic panels and doors for seafood factory

Installing a blast chiller for a seafood factory

Installing hygienic panels for a seafood processing facility

£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

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

One Hour Fire-Rated Hygienic Room for Food Technology Business

Taste Tech

Background

Having previously worked with Taste Tech Limited on a confectionery laboratory, we were delighted to be working with them again on their new hygienic bakery.

Requirement

As a research and development company, Taste Tech needed a bakery in which to test a range of performance-enhancing solutions. The food-safe panel finish enables them to keep the environment hygienic. Flour is highly explosive so Taste Tech also required a 1-hour fire rating for the panels and air ventilation systems.

Solution

A 1-hour fire rated hygienic room measuring 5.00m x 8.00m x 2.70m high using Eurobond mineral fibre cored panel with a food-safe polyester finish. Two fire-rated hinged personnel doors and a vision panel. Two in-tumescent air transfer vents.

We completed the project on schedule and will be working with the client on a new project shortly.

We were very happy with the work you did for us, in fact we have already recommended your services!

Peter Sargent, Taste Tech Ltd

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Completed installation of fire rated bakery unit in Bristol

Completed fire rated bakery on site under mezzanine floor

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

Flour Mill & Factory Partitions, Berkshire

Specialist Flour Producer

Background

Due to unprecedented demand for their specialist products, this Berkshire-based mill built an extension to their existing facility.

Requirement

A series of 4-hour and 1-hour rated firewalls and 1-hour fire rated staircase enclosure, with accompanying fire stopping products, to form a new factory extension mill/production facility.

Solution

The broad range of applications for our industrial partitioning system was put to the test on this project. Not only were we asked to provide the 4-hour firewalls, we also found a solution that provided the 1-hour walls and encompassed the necessary hygienic requirements for a company making products for the food industry.

Let people know that you have another satisfied customer!

Factory Owner

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Fire rated composite panels for flour mill project

Food Manufacturing Training Centre

Peterborough Regional College

Background

Stancold secured a competitive tender to build the Food Centre of Excellence and Training Facility for Peterborough Regional College. The centre will train students in a range of skills including product development and food production.

Requirement

Over 1,200m² of multi-coloured external panels to provide both the necessary fire rating and weatherproof finish as well as the internal hygienic finish for the newly built facility. Internally, the client required multiple hygienic food-safe areas, changing rooms and corridors.

Solution

We matched the external panels to the college’s colour scheme. A project of this scale needed significant delivery access, but by coordinating our plans with the schedule of the busy college campus we overcame any potential safety concerns.

We appreciate the knowledge and experience that both the Lindum Group and Stancold brought to the project to enable us to achieve our goals.

Barbara Grange, Director, Peterborough Regional College

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Food Manufacturing Training Centre, Peterborough

Specialist Sake Chiller, London

Japanese Beverage Distributor

Background

A new client required our expertise to build frozen and chilled storage alongside a distribution warehouse for Europe’s biggest importer and developer of Japanese food and drink.

Requirement

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

Solution

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 and because of the high value and storage requirements of Sake, a separate chiller was created, alongside the vegetable chiller for fresh produce. To keep the products at the correct temperature during loading we also installed a dock chiller.

It was an exciting project that required us to provide solutions for different food and drink products as well as the different stages of storage and distribution

Sam Glover, Contracts Manager, Stancold

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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.

New technology enables control of the store temperature remotely

Gary Howells, Project Manager

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Distribution Warehouse Installation

Food Distributor

Background

As part our client’s exciting UK expansion plans, we were awarded their newest temperature controlled distribution warehouse installation. The facility, located in London, is their principal warehouse for food distribution.

Requirement

Stancold installed a combination of temperature controlled areas complete with refrigeration over an impressive 5800 m². This includes a large freezer, five chill rooms for various food products, a food preparation area and marshalling areas. We also installed fire-rated office partitions over two levels.

Solution

Drawing on years of experience in distribution warehouse installation, our design team came up with an energy efficient building plan. This was perfect for the storage and preparation of a variety of chilled and frozen foods. The rooms were sized around the client’s racking storage needs, providing the best use of space.

We handed over a fully equipped and operational state-of-the-art facility on the agreed deadline.

Excellent service throughout.

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Distribution warehouse rapid roller doors

Distribution warehouse installation with racking

Chiller & Meat Preparation Area

Bakers of Nailsea

Background

Bakers of Nailsea are a small family-run retail butchery and abattoir based in North Somerset. Established over 100 years ago, the business supplies responsibly farmed, high-quality meat produce to customers all over Somerset and Devon area.

Requirement

As a returning customer of Stancold, on this occasion, we were appointed to create a dual-compartment chiller and production area equipped with an airlock system in order to expand their existing operation.

Solution

By working closely with the client, we ensured that our works didn’t disrupt their current production capacity. We used Kingspan coldroom panels to create the rooms and partitions and specially manufactured doors to enable the client’s meat rail system to be fitted into the scheme seamlessly. We’ve included an external sliding coldroom door with an airlock to keep the temperatures constant within the areas.

Brilliant product and installation. I found your Project Manager and whole team very easy to deal with.

James Baker, Bakers of Nailsea

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Cold Rooms for Food Preparation Area

Project Link / Flying Fish

Background

Stancold were appointed by Project Link, food industry construction experts, to assist with the extension and refurbishment of a large fish processing and preparation area for Flying Fish Seafoods in Cornwall. Flying Fish Seafoods are suppliers of high-quality fish to restaurants and hotels all over the South and West of England.

Requirement

The requirements were over two phases; the first phase was to form a chilled fish preparation area in the newly built extension. The second phase was to rip out and reinstall a new chill store and processing area linked to the newly built preparation area. The lobster unit was part of an additional phase added later in the project.

Solution

Causing no disruption to production and observing strict site requirements, Stancold worked closely with Project Link over 3 phases to meet tight deadlines. With the creation of suitable temperature-controlled fish processing and a preparation area, this enables Flying Fish Seafoods to grow its product line with lobster.

The installers were excellent. Overall, a good experience.

Chris Smith, Project Link

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New Bakery Build

Artisan Bakery

Background

Stancold were appointed to build a new bakery and fit out the production facility for an award-winning family-run bakery in Somerset.

Requirement

To design and install a walk-in freezer store and chiller, hygienic storage and production areas, changing rooms and stairwell over 2 levels in a newly built bakery.

Solution

Working closely with the customer to develop the preferred layout design, accommodating their production needs and liaising with builders from the initial stages regarding access, machinery, delivery and lifting of products.

The whole job was very good and completed in the agreed timescale.

Michael P., Operations Director

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Bakery Extension

Marshfield Bakery

Background

Marshfield Bakery are an award-winning family-owned business established in 1984. They manufacture over fifteen different flavours of shortbread and flapjack products and a variety of cakes and biscuits. Due to the popularity of their products, they have expanded 3 times over 30 years, most recently in 2015.

Process

This project required an increase in capacity of Marshfield Bakery’s headquarters, by creating additional production and storage areas including an NPD room and a ‘drive in’ chiller.

Project Delivery

By removing and disposing of old panels, panelling the new extension with food-safe walls and installing a walk-in chiller, Stancold have created the right conditions for the introduction of a new product line. Worthy of a royal visit, the new bakery was officially opened by HRH The Countess of Wessex GCVO on 10 September 2015.

You did a brilliant job. We are really pleased with the result.

Chris Smith, Marshfield Bakery

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walk in cold room for bakery building, walk-in chiller

coldroom for bakery building, walk-in chiller

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hygienic food safe corridors and a blast chiller area

Yogurt Processing Area

Rachel's Organic

Background

Based in Aberystwyth, Rachel’s Organic is one of Britain’s fastest-growing organic dairies. The company’s products are made using only fresh liquid milk sourced from approved organic farms.

Requirement

I was very satisfied with Stancold

Tim Pink, Rachel's Organic

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temperature controlled production and packing area

External Clad Coldstore

Food Factory

Background

This food company’s range of business includes dairy and meat processing, liquid milk production, animal feed manufacture and grain trading.

Requirement

Design, supply and install external clad coldstore with integrated envelope system to provide the building with an internal chill temperature of +4˚C, without the need for a separate chillstore ‘box’ within the structure.

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Chiller Extension

Online Supermarket

Background

A well-known online supermarket service devoted to making their customers’ lives easier and offering the highest standards of service.

Requirement

Design, supply and install a new hygienic food-safe chilled facility for food packaging and distribution, plus refurbishment of many existing ceilings and insulated panel walls.

Quality of products and installation is very good,
what it says on the tin

Construction Project Manager

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cold rooms for food distribution building

Food Processing Area

AB Produce

Background

AB Produce supply a range of potatoes and prepared vegetables to the wholesale, retail, processing, catering and foodservice supply chain.

Company

One of the world’s largest logistics organisations, Kuehne + Nagel, employs more than 42,000 people at 750 locations in 100 countries. Kuehne + Nagel Drinks Logistics is a newly formed and wholly owned business within the group, providing a national platform for the distribution of drinks, alcohol and associated services to retail outlets across the UK.