The Project

We were approached by Simply Fresh to manufacture and install a bespoke wash wall onto an existing production gantry following a recommendation from a BRCGS inspection.

The recommendation was to introduce an additional wash wall to help prevent overspray during cleaning operations, reducing the risk of water and cleaning contamination reaching other products or surrounding production areas.

The challenge was to design and manufacture a new wash wall that would replicate the existing installation while fitting seamlessly onto the customer's current gantry structure.

Our Solution

To ensure the new wash wall matched the existing installation, our first step was to visit the site and take accurate measurements of the original wash wall positioned at the opposite end of the gantry.

Using these measurements, we replicated the existing design and developed a bespoke fabrication solution to suit the customer's requirements.

The manufacturing process involved folding sheet metal to achieve the required shape and dimensions, before joining the individual metal sections together to create the finished structure.

We also fabricated and welded two lifting handles to the top of the wash wall. These were incorporated specifically to allow the structure to be safely manoeuvred and positioned during installation.

Fabrication & On-Site Installation

Once fabrication was complete, our team returned to site to carry out the installation.

Due to the size and weight of the structure, careful consideration was given to how the wash wall would be lifted, handled and positioned. The integrated lifting handles allowed the structure to be manoeuvred into place, enabling our team to securely fit the new wash wall to the existing gantry.

The installation required careful positioning to ensure the new section aligned correctly with the existing structure and provided the additional protection required during cleaning operations.

The Result

The completed installation provided Simply Fresh with a bespoke wash wall that replicated their existing design while addressing the recommendation raised during their BRCGS inspection.

The additional barrier helps contain overspray during cleaning, reducing the potential for cross-contamination between products and improving protection within the production environment.

Another tailored fabrication project delivered by our team, from initial site measurements and design replication through to manufacture, welding, and on-site installation.