New Beef and Lamb Chill Pipework - Dawn Meats Kildare 

Dawn Meats is one of Europe’s leading food companies, supplying a wide range of food products in over 50 different countries. With 11 different sites in Ireland, Kildare chilling is one of the newest operations from the Dawn Meats group. With more than a staggering 2700M worth of pipework installed, it was one of our largest, and proudest operations to be a part of.​

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The Challenge

With this being a large-scale revamp, the challenge is always to ensure quality over quantity. An impressive 3227 hours were spent on this project alone. That is over 400 days’ worth of work for one person to complete. 8 new beef chills, 4 lamb chills, multiple detain and holding rooms, as well as a plant room with a 6Mx2M Vessel, all insulated by team Technotherm.

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Project Objectives

There were multiple factors and objectives within this project:

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• Ensure the completion target was achieved so the factory could continue processing food products safely without disturbance

• Proactive planning to reduce downtime due to weather restrictions

• Ensuring the health and safety of all team members and members of the public that were involved

• Maintaining high health standards whilst working in a live production environment

• Completing each targeted area/sector to the required standard of a world class food factory

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Success was defined as:

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• Completion within the agreed timeframe

• Delivery within budget

• An effective solution to reduce the heat loss of the new ammonia system

• Maintaining safety standards throughout a live production environment

• Achieving high standards of quality in our Foam in place injection system

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As always, execution quality, safety, and program adherence are critical measures of success.

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Our Solution & Approach

Upon arrival on site, our team was inducted and ran through the health and safety procedures adherent to the site. They then split up to ensure all materials were accurately supplied, stored safely, and ready for the works to begin

To ensure smooth operations, our teams cladded from coolers to main headers, and followed that process whilst foaming and insulating to ensure minimal effect in production, as well as a consistent foam density throughout.

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Scope of Works Included

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• Application of Dinitrol corrosive protection agent to all pipework

• Installation of Black Aluminum Cladding with practical application of silicone for further vapor sealing

• Insulation using Foam in place injection insulation.

• Vapor sealing of all other exposed areas using silicone and fosters

• Cleaning of all cladding and debris to ensure an aesthetic masterpiece.

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This approach ensured smooth operations, a professional finish, advanced thermal performance and the durability to last years.

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Delivery & Execution

Work was carried out in controlled sectors or areas to assist the factory in running their operations as soon as possible. Those specific areas or sectors were actioned and then turned live upon completion to ensure the factory could continue with their operations.

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1. Plant room pipework with NH3 vessel completed

2. Main headers from plantroom to rooftop completed

3. Big vac pac chills completed

4. Small vac pac chills completed

5. All lamb chills completed

6. All beef chills completed

7. Complete site survey and thermal imaging report to sign off completed works

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Client Communication

Clear communication was a priority throughout the project. A dedicated WhatsApp group was used to:

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• Provide daily and monthly progress updates.

• Share photographs of completed sections and utilized as a platform for any and all technical questions.

• Outline targets for the next area or sector

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This ensured full transparency and granted the client a platform to track progress in real time, allowing the client to operate remotely during the process.

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Safety Considerations

Operating on a live construction site, which simultaneously operates as a live production facility can be tricky. Ensuring all safety procedures are followed, correct PPE is worn and reducing impact to the health and safety standards of the production facility are of the upmost importance. Facilities such as Dawn Meats carry a high standard of operations to ensure only the best quality food products are supplied.

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Why This Matters

This project demonstrates our ability to:

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• Work safely in complex environments under construction as well as where food safety is of the upmost importance.

• Deliver high-quality insulation solutions within approved timeframes and above our client’s expectations.

• Minimise operational risks and downtime.

• Maintain exceptional communication and site standards in complex industrial environments.​​​