Muller Dairy Factory

Scope of Work: Müller Dairy Factory, part of the Müller Group, employs over 32,000 people across Europe and plays a significant role in the UK dairy industry. In the UK alone, Müller works with 1,300 British farmers to develop, manufacture, and market a wide range of branded and private label dairy products. As one of the largest dairy companies in Europe, maintaining the factory’s efficiency and productivity while making significant process improvements is crucial to the business’s success.

As part of a major upgrade to the processing areas within the factory, two large warehouses required the installation of new HVAC equipment to optimise air quality and temperature control. This involved creating large openings for air handling ducts to pass through the existing 1st and 2nd floor concrete slabs. However, the installation had to be completed while the factory remained fully operational, meaning any disruption to production had to be minimised. The challenge was ensuring that the structural integrity of the concrete slabs would be maintained despite the creation of these large openings, which involved cutting through the existing reinforced concrete.

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To overcome the challenge of maintaining the strength of the concrete slabs while introducing new openings, carbon fibre strengthening was selected as the most effective solution. Carbon fibre was chosen for its unique properties: it is incredibly strong yet thin, allowing it to reinforce structural elements without adding significant weight or thickness. Additionally, carbon fibre can be installed quickly, making it ideal for projects that need to minimise disruption.

CCUK’s team of expert installation technicians were brought in to apply their specialised carbon fibre strengthening system, Fibre wrap, around the newly created riser openings. The concrete surfaces surrounding the new ducts were carefully prepared, and two layers of Fibre wrap were applied to the affected areas. This advanced system ensured that any stresses caused by the cutting of the original reinforcement were effectively transferred, maintaining the structural integrity of the concrete slabs.

The carbon fibre strengthening system was able to bolster the slabs without the need for invasive construction techniques or extended downtime, ensuring that the new HVAC systems could be installed while the factory remained fully operational.

By using carbon fibre strengthening, the project was completed efficiently and with minimal disruption to the factory’s ongoing operations. The installation of the new HVAC equipment was seamlessly integrated with the factory’s existing infrastructure, ensuring the structural integrity of the floors was maintained despite the cutting of new riser openings.

The collaboration between Müller Dairy Factory, the contractors, and CCUK ensured that the works were completed on time and within budget, allowing the factory to continue its operations without interruption. The use of carbon fibre strengthening not only provided a quick and effective solution but also highlighted the adaptability of this technology in high-demand industrial environments.

Müller Dairy Factory is now equipped with an improved HVAC system, supporting their ongoing commitment to efficiency and product quality while safeguarding the factory’s long-term structural integrity.