JWCI works on world’s largest fresh milk Dairy

Global Dairy Company Arla Foods is renowned for its craftsmanship and commitment to the environment. Its new £150m dairy facility is no exception to this rule and Staffordshire based Process Engineers JWCI were on site to help. 

The new super dairy at Aylesbury, commissioned to provide a strategic base to service customers in and around London, has the capacity to process up to one billion litres of fresh milk and will be zero carbon, ensuring its environmentally sound credentials. 

Arla Foods brands include Anchor, Lurpak, Cravendale, Apetina and Tickler and is the UK’s number one provider of butter and spreads with a £2 billion turnover.

The contract for the chemical distribution at the new 70 acre Aylesbury site was awarded to Ecolab GMBH. JWCI have worked with Ecolab UK for many years but had previously only worked on smaller scale projects for the German company. JWCI invited the project leaders from Ecolab GMBH to their offices in 2012 so they could meet the team and see how JWCI’s experience and skills could benefit the project.

Kerry Callear, Company Director said;
“It was important for us to prove our level of competence aswell as our ability to meet all timescales and manage efficiently. We knew we had the capability so we just wanted to show that to Ecolab GMBH from the outset.”

Having worked in the food industry for many years JWCI have built up an enviable reputation for their high standards of professionalism so the relationship with Ecolab GMBH and the Arla project developed from there. 

JWCI were first on site for Ecolab in January 2013 to organise the early stages of the project and by February were designated to undertake the whole mechanical installation within the chemical room and service corridors to provide connection points to two other firms joining the site the following month. The team consisting of JWCI, a second British firm and a company from Germany worked alongside each other to then complete all chemical distribution plant and pipework throughout the factory. JWCI were last to leave site having completed all services during commissioning in November 2013.

Work undertaken included positioning tanks, installing brackets and all pipework, fabricating and installing walkways, gantry and staircases. JWCI also supplied the majority of pipe and fittings for use on the site by the three teams. 

One of the two completed tank installations with bespoke stainless steel gantry. 

JWCI were responsible for all new pipe work throughout the chemical room 
along with the gantry and equipment installations.

Major Project for Ecolab by JWCI Ltd

JWCI ltd are pleased to have been awarded the contract for a major restructure and refit at the Northwich Cheshire site for the global leader in the hygiene industry, Ecolab.This prestigious contract was awarded to JWCI after the world’s largest sustainability services company, Nalco merged with hygiene giant Ecolab.  

The merger means Ecolab now have over 41,000 employees in more than 170 countries. Founded in 1923 the merger brings together two highly complimentary industries to provide global sustainability services and hygiene solutions across the food, beverage, hygiene and medical industries.

The joining of the two businesses saw the Ecolab manufacturing facility at Cheadle Hulme being relocated to join the larger Ecolab/Nalco site at Northwich in Cheshire. 

JWCI have worked on projects for Ecolab previously and proved to be highly competent in their professional manner and expertise both on site and in the design and manufacture stages. 

Rob Pettener from Ecolab UK said “JWCI proved to be a reliable and flexible contractor to EcoLab. JWCI are well known and respected within the industry and have clearly demonstrated a track record to deliver on large and complex installation projects.”

Phase one of this large project was undertaken by JWCI in partnership with Ecolab’s onsite team and  proved such a success that JWCI became solely responsible for Phase two.

Phase one of the contract, which began in December 2012 included supply and installation of pipe work, removal and installation of tanks and mixing vessels plus supply, fabrication and installation of new tailored pipework and mezzanine floor supports. The later phase involved the strip out of the new site which included provision and management of crane lifts and providing all required health and safety documentation surrounding this. JWCI provide a full design, manufacture, installation and maintenance service to their customers and this streamlined ‘one supplier’ approach means greater peace of mind for the client. 

The larger second phase, a complete strip out and replacement project, included decommissioning of existing mixer tanks and pipework plus installing new steam lines, steam traps, valves and instrumentation. New gantries and pipework were fabricated and installed by JWCI’s highly experienced on-site team.

JWCI work to the highest safety standards and are compliant to all current British health and Safety guidelines and best practice schemes. JWCI are proud to be ISO 9001 registered and SafeContractor accredited. They are also CHAS approved and registered with Constructionline to provide the highest standards whilst on-site. 

JWCI’s expertise in providing bespoke solutions tailored to their customers exact requirements meant that Ecolab could streamline their processes and improve efficiency and be assured of excellent workmanship. This coupled with the high level of customer service provided by JWCI meant a winning combination. 

Working in Partnership to provide a complete solution

It’s important to us that we are able to offer all our customers the best and most complete service. 

As part of that commitment we work with LivEarth Electrical Contractors on all electrical aspects of your project so you can rest assured this is taken care of by the experts in their field. 

All work is carried out by fully qualified electricians who are registered with a competent person scheme and are fully insured.
From Industrial and PLC control systems to HMI we can design, construct and install equipment for a wide range of customers in the dairy, food, chemical and other process industries using only quality parts from leading manufacturers.

JWCI & LivEarth offer:

Industrial control system design, manufacture and installation. 
PLC Control System integrators
Human Machine Interfaces (HMI’s) selection, programming and support.
PLC control systems and control panel design
Programmable Logic Controllers (PLC’s) programming service.
Parts from the world’s leading manufacturers including Mitsubishi, Omron, Schneider, Siemens, Crouzet, Allen Bradley and more. 
Electrical Testing Services & Inspection

JWCI & LivEarth Maintenance:

Packages tailored to your business.
Upkeep of control panels to a standard required by Health & Safety. 
Preventative maintenance including Thermal Imaging Inspection. This has proved highly successful meaning major cost savings for our clients.
PLC Software backup.
24 hour call out service available for emergencies.

For more information on parts ordering, products or any other services offered by JWCI Ltd please call Kerry on 01889 507177. 

JWCI Ltd - Investing in the future

JWCI Limited is a long established company, located in the heart of the UK with our Head Office in Cheadle and manufacturing facilities in Fole, Uttoxeter. We design, construct and install processing equipment for a wide range of customers in the dairy, food, chemical and other process industries.

The current economic climate is proving tough for many businesses but JWCI are ‘bucking the trend’ with big plans over the next 12 months. 

With many years in the industry under their belt  JWCI are investing in a site expansion of their current manufacturing facilities in Fole. The expansion will improve facilities and help meet the increasing demand for high quality engineering.

The larger workshops and improved employee facilities will increase productivity and allow JWCI to undertake larger commissions in-house and reduce manufacturing times.

There will also be a new testing facility for skids and equipment to minimize commissioning on site. 

Holding a larger range of parts in permanent stock, thanks to the new expansion, will reduce delivery times even further for customers ordering plant processing equipment 7 days a week. An important service when plant down time can be so costly for manufacturers.

All this means that JWCI will now be offering a two year guarantee on all their prefabricated work as standard. This increase, from the usual 12 month guarantee offered by many of their competitors, highlights the assurance they have in their products being of the highest quality.

The site expansion is due to be fully operational by July 2012 so why not pay us a visit?

For more information on parts ordering, products or any other services offered by JWCI Ltd please call Kerry on 01889 507177. 

Racking Systems - Flexible Storage

Where storage is an issue JWCI have the ideal solution, designed and built to your requirements. We understand the importance of environments within the Dairy industry, so can advise you on the best type of equipment to use, where there is not a suitable “off the shelf” solution we, design, build and install bespoke racking systems to suit your individual needs.

As standard we offer:

•  Free site visits to assess your needs  
•  Designed, manufactured & installed to your requirements     
•  Fast, efficient installations by our experienced site team
•  Full after sales service & maintenance package

Storage can be a problem for many businesses and can even prevent further growth. By increasing space and using existing space more efficiently you can produce, store and ultimately, sell more product.
We are tried and tested within the Dairy Industry and can supply full hygienic tracked racking systems designed, manufactured and installed by JWCI. Our systems are easily moved by just one operative and remove trip hazards for a safer working environment. We can also supply high quality mobile racking.
Our solutions are not available from anywhere else in the UK so please call us today to discuss your individual requirements further.

Please visit www.jwciltd.com or call 01889 507177 for further information.

SAFEcontractor Accredited

JWCI Ltd is again proud to be one of the latest group of companies to join a leading edge scheme, designed to help industry improve its safety record. JWCI Ltd have achieved the SAFEcontractor status for the last few years and are pleased to say have been successful again this year. 

The Staffordshire based firm received accreditation from SAFEcontractor, a programme which recognises very high standards of health and safety practice amongst UK contractors. 
Employing 12 people JWCI Ltd is principally involved in the dairy, food and chemical industries with a proven track record for high quality and professional service. Recent clients have included Quenby Hall Dairy, one of only six ‘Stilton’ cheese makers.

“We felt it was important to become SAFEcontractor accredited in order to highlight to potential customers our dedication to best practice and quality of service” Kerry Callear, JWCI Ltd

The company's application to receive SAFEcontractor accreditation was driven by the need for a uniform standard across the business. 
SAFEcontractor accreditation is expected to enhance the companys ability to attract new contracts and its commitment to safety will be viewed positively by insurers when the company liability policy is up for renewal.
SAFEcontractor accreditation is applicable to most sectors although it is particularly relevant to food manufacture, property, facilities management, retail and leisure sectors, all of which are big users of contract services.
John Kinge, Head of Risk at SAFEcontractor said “Major organisations can no longer run the risk of employing contractors who are not able to prove that they have sound health and safety policies”.
“More companies need to understand the importance of adopting good risk management in the way that JWCI Ltd has done. The firms continued high standards set an example, which hopefully will be followed by other companies within the sector”.
Under the SAFEcontractor system, businesses undergo a vetting process, which examines health and safety procedures and their track record for safe practice. Those companies meeting the high standards are included on a database, which is accessible to registered users only via a website, www.safecontractor.com.

Please visit www.jwciltd.com or call 01889 507177 for further information.

Hygienic Cooling Systems

We understand the importance of environments within the Food industry, so can advise you on the best type of cooling equipment to use. We design, manufacture and install bespoke cooling systems to suit your individual needs.

As standard we offer:

•  Free site visits to assess your needs  
•  Designed, manufactured & installed to your requirements     
•  Fast, efficient installations by our experienced site team
•  Full after sales service & maintenance package

We have worked within the food industry for many years and can help advise on the best solution for your needs. Systems can be sized, designed and built to suit your needs - all in the UK using high quality materials.

We supply JLC single or double coolers which can be floor, ceiling or wall mounted to minimise required space and are fully hygienic and easy to dismantle for cleaning. 

Systems can be fully automated and we work with LivEarth Electrical Contractors to provide a complete service to our customers from design and manufacture to installation and maintenance.

Please call us to discuss your requirments further.