This project involved the design and construction of a seven-tier steel mezzanine structure within a warehouse handling dairy products. The warehouse featured both chilled and ambient temperature zones, necessitating careful consideration of temperature control to maintain product quality. The mezzanine was specifically engineered to integrate seamlessly with a new automation system aimed at modernizing the facility's operations.
CUSTOMER
Müller UK & Ireland develops, manufactures and markets a wide range of branded and private-label dairy products. Müller Yogurt & Desserts, one of the company’s three business units, is headquartered in Market Drayton, Shropshire. Alongside plants in Telford and Minsterley, the Market Drayton facility is responsible for producing some of the UK’s favourite chilled brands, including Müller Corner and Müller Rice.
PROJECT
Despite having a number of warehouses on the Market Drayton site, Müller needed additional space for product storage. It also wanted to install automated logistics equipment in both chilled and ambient temperature zones, working in partnership with system integrator, Dematic. The extra storage space took the form of a fully automated store, comprising a seven-storey steel structure served by transfer cars, pallet lifts and conveyors. In addition to the steelwork for the store, MiTek supplied the u-shaped steel channels to support the 3m-high insulation wall panels around the storage area.
CHALLENGE
This project posed a number of challenges:
→ The new store occupied a space that was long and narrow (68m by 8m), which meant tight working conditions.
→ The steel structure was not only within a fully operational warehouse, but also a refrigerated facility (maximum 5ºC).
→ Without access doors, everything had to enter the site through either a wall or the roof.
→ The mezzanine design needed to take account of the fact that the existing slab was being used.
SOLUTION
Meticulous planning by the MiTek team ensured successful installation, phased over a six-month period:
→ Low-profile sections were used to suit the restricted space, with all columns designed to be spliced together on site.
→ A section of the warehouse roof was temporarily removed while all plant and components were craned in.
→ To ensure optimum efficiency for the cooling technology – located on levels 3 and 7 – self-supporting mesh flooring was used instead of joists, maximising cold air circulation between all levels.
BENEFITS
Through intelligent design of the steel structure and excellent project management, the MiTek team helped secure a number of benefits for Müller:
→ Seamless integration with the automated logistics systems.
→ Cost-efficient use of the existing slab.
→ Delivery on time and with minimal disruption to ongoing operations, through detailed planning and collaboration with other trades working on site.
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