Expanding chilled food production facilities in existing buildings

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The synergies of the Styne Group are highlighted in this project where Styne Engineering worked alongside Styne Industrial Refrigeration and Styne Electrical to expand the food production capacity of a local business.

Brief

One of our regular customers asked us to develop a feasibility plan and costings to see if they could expand the floorspace of their food production facilities within their existing buildings.

On the completion of the plans and costings, Styne Group was asked to manufacture and install the complete system.

Project Information

The project highlighted the benefits of using the Styne Group as we were able to assemble a dedicated team of specialists from across the organisation that managed every stage of the project.

Upgrading the customer’s existing refrigeration system required the design and installation of complex pipework to deliver both ammonia and glycol to five new evaporators. The evaporators had to be installed in a confined roof space in order to cool the new food preparation area.

We designed and installed structural steel work to support new evaporator units from the new portal frame building in record time to allow the building contractor to maintain their schedule. Once the insulated ceiling panels had been installed, we installed five evaporators sized to cool the new area to a controlled 3°C.

Working to specifications provided by Styne Industrial Refrigeration, our engineering team installed 104mm stainless steel pipe work to supply the secondary refrigerant (Glycol) ring from plate heat exchangers to the evaporators. Individual automated modulating valve stations were welded and supported from our secondary steel work in the roof void local to each of the evaporators.

Due to limited access and space in the cramped roof space, our design team carried out site surveys allowing us to pre-fabricate a pump and heat exchanger skid to be sited in the roof void.

With the skid in position, we completed the job by breaking into the factory ammonia system whilst the customer’s production line was idle over a weekend, so as not to affect their productivity.

We installed the new heat exchanger and pump skid and connected the required ammonia pipe work to the equipment within 48 hours.

Before the production line was restarted on Monday morning, we had carried out all of the required NDT testing to the carbon steel ammonia pipe work and pressure tested both the ammonia and the glycol system prior to sign-off by the customer.

All welds were carried out in accordance with BS EN15614-1 qualified weld procedures by our welders who are qualified to BS EN9606-1.