The Brief
A major dairy cooperative in Friesland needed a new UHT processing and aseptic packaging line to meet growing demand for long-shelf-life products. The line had to be installed inside their existing factory — which was producing 24/7 and couldn't stop.
The Challenge
Installing a complete new processing line in an operating dairy factory without a single unplanned production interruption. The existing CIP system couldn't support phased commissioning. The FSSC 22000 certification audit was scheduled before the first commercial product run — there was no margin for rework.
Our Approach
We redesigned the CIP routing to allow phased commissioning — each section of the new line could be cleaned and tested independently while the old line kept running. We ran a shadow HACCP validation alongside construction, so the food safety documentation was being verified against the physical installation in real time, not reconciled after the fact. We managed 14 contractors simultaneously on a site that never stopped producing, with a construction schedule built around the factory's production breaks.
Results
Zero unplanned production stoppages during 9-month construction
FSSC 22000 surveillance audit passed first time
18% energy reduction vs. old line (heat recovery integration)
Delivered €340K under budget (procurement savings passed to client)
"We installed a complete new processing line without a single unplanned production stop. I didn't think that was possible in our facility."
— Plant Director