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Despite times of crisis, Tican Fresh Meat has experienced massive growth in recent years. The number of weekly slaughterings has increased from 34,000 to 38,000 at the slaughterhouse, and the growth is expected to continue. As a result of this, Tican has invested approx. DKK 85 million in optimizing the refrigeration system to secure the best possible product quality with the lowest possible costs.
“The major investment was necessary to secure optimal meet quality of our products now as well as in the future. At the same time, I believe that we can obtain an annual saving of DKK 4 million as the cooling loss will be reduced from approx. one and a half percent to one percent,” said Ove Thejls, CEO of Tican Fresh Meat.
Future-proof refrigeration with focus on environmental safety
As main consultant, ALECTIA, together with the Danish Technological Institute, has prepared a design proposal for the new chill tunnel which has replaced an outdated and worn-out model. In the project planning, ALECTIA has considered parameters such as cooling loss, increased yield, salary savings, energy consumption, expenses for maintenance and cleaning, etc., and has been in charge of the entire building process.
In the new chill tunnel, the warm slaughtered carcasses are cooled down with cold air. An automatic conveyor system leads the carcasses into the equalization chill rooms where they are suspended for 16-24 hours at approx. 5°C to obtain a uniform meat temperature.
The new refrigeration system includes an ammonia-based refrigeration plant, and ALECTIA has been responsible for the authority applications and approval at the Danish Environmental Protection Agency. As part of the design proposal, the cooling valves and pipes of the chill room are placed in a separate service area inside the slaughterhouse instead of directly on the roof in order to reduce the environmental and safety-related risks by using ammonia as refrigerant.
Great satisfaction at Tican Fresh Meat
The construction process started in October 2013, and in May 2014 the new chill tunnel was commissioned. They express great satisfaction at Tican that the project was completed on time and without any noticeable budget overruns.
”The quality of the completed project meets our expectation of a good quality solution as regards both design and execution. This also applies to the consultancy of which ALECTIA has been responsible during the entire project implementation process,” said Jens L. Rasmussen, Technical Manager of Tican Fresh Meat.
Accurate project design and resource efficiency
One of our largest pharmaceutical customers has initiated a project involving the reconstruction and replacement of the refrigeration plant, ventilation systems, BMS and electrical supplies at a 10,000 m2 factory.
As part of the project, the old ventilation systems will be lifted out of the 5 technical rooms in the factory and replaced with fewer and larger plants on the roof. Simultaneously, the solution will provide the customer with modern, energy-efficient equipment and free more space in the technical rooms.
At the same time a new refrigeration plant will be established, a number of old building services on the roof will be demolished, and pipes and cables will be run from the new plants down to the technical rooms. One of the challenges is to stay clear of existing refrigeration systems, piping and roof light installations, etc.
Due to the complexity of the project, traditional measurement and data registration methods would have been highly time-consuming. The use of 3D laser scanning and modelling has helped to ensure a quick and smooth process. A detailed mapping of existing and future building services has facilitated the planning and coordination processes significantly, resulting in reduced costs in terms of time and money.
3D scanning and modelling in practice
The task has been carried out in cooperation with a subcontractor specializing in laser scans. Using scans from 15 measuring points, the entire roof and all the building services have been mapped down to the smallest detail (+ / – 2 mm) in a so-called point cloud. The laser scanner also took visual images for 3D modelling.
The roof and all the building services were mapped in a point cloud based on approx. 15 measuring points.
By converting data from the photo images and the point cloud into 3D objects such as roofs, hoods, refrigeration and ventilation plants, we created a complete 3D model of the building and the roof showing both existing and future building services. It was then easy to design the new plants on the roof while taking the existing facilities into account.
Scanning facilitates prefabrication
3D scanning and modelling was also used on a technical floor of approx. 1,000 m2 where existing ducts to the production areas will be connected to the new manifold and ducts running from the roof. This task required a scan head with a finer resolution, and accurate 3D scans have made it possible to prefabricate ducts and adapters externally so that the building services can be implemented quickly with minimal disruption to the production.
Technical floor with the roof removed. Grey building services are pre-existing, coloured building services are new.
Laser scanning pays off
While 3D laser scanning is a resource-intensive method, the investment can pay for itself in man-hours saved on measuring, registration and design processes. The method ensures that all essential data are registered quickly, efficiently, and with great accuracy. It shortens the process between idea and implementation, making it easier to plan and coordinate the work in the project design phase. At ALECTIA, we have positive experiences in using the tool, which is more and more commonly used.
From conceptual design to site supervision
As full-service consultant, ALECTIA has handled the project all the way from conceptual and basic design to detailed design and tender. In the ongoing implementation phase, which is expected to run throughout 2014, we are responsible for construction management, security management and technical supervision.
The Russian company Kungurskiy Agroholding entrusted ALECTIA to carry out the preliminary planning of a new food plant in the Perm region. The current production will be expanded and relocated from an existing site to a new combined production site which will house both a dairy and a facility for slaughtering and processing pigs, cattle and lambs.
The project is the result of Kungurskiy’s development into a leading local producer of quality food in the area within the last decade. This requires an expansion and efficiency optimisation which should be achieved by the new plant.
The combination of dairy, abattoir and meat processing is unusual but advantageous with regards to both production and distribution costs. The combination of the production units means savings on administration, energy supply and waste water plants. The project has required a detailed analysis of legislation, logistics and food safety managed by ALECTIA.
A group of ALECTIA’s process engineers and architects with experience from several dairy and meat projects in both Denmark and Russia have established the overall frames of the project in the Master Plan, including time schedules and investment budgets.
Modelled on the European food industry
In Russia it is not unusual for large agricultural companies to control the primary production as well as processing and distribution. The Russian agricultural sector is expanding rapidly these years, and the country’s entry into the WTO means even greater demands on efficient planning and production.
The consulting services of ALECTIA on optimising and planning the entire supply chain are requested by several Russian companies. These companies require that new factories are established with the same focus on productivity and food safety as in Europe.
Creating a productive working environment is about adjusting the three primary factors that affect your employees’ ability to work effectively: leadership, health and safety. We believe that the employees deliver the results and that an integrated approach increases the productivity in a workplace.
We know that investing in a good working environment contributes to maintaining and improving a company’s productivity and image. We also know that providing useful occupational health and safety advice is not just about strong skills but requires a thorough knowledge of the market in which our customers operate. Based on our extensive trade knowledge we can provide advice that goes straight to the core of our customers’ challenges. We transform ideas, thoughts and strategies into concrete initiatives that create positive results on your bottom line.
ALECTIA offers a variety of services ranging from advice on the physical and psychosocial working environment, acoustics and noise, chemicals and biological hazards, health and safety, stress and well-being to management training and organisational development.
We are licensed by the Danish Working Environment Authority.
Our position as leading adviser on production facilities and process equipment requires both in-depth knowledge of the industry and an understanding of the client’s end product and production processes. ALECTIA has extensive knowledge on the production processes specific to the industrial segments we work with. Our experts specialise in planning and designing process facilities for anything from raw material reception to processing, production, bottling/packaging, logistics and storage.
We provide engineering advice during all process phases – from clarification, analysis, design and planning to tender and project realisation. We review new plants and advise on facility expansions, refurbishment and upgrades.
Combining our process engineering skills with a deep business understanding and specific trade knowledge we help our clients focus on business-critical areas. Our consulting approach also ensures that projects live up to all quality, financial viability and production efficiency requirements.
We help our clients find the right technical solutions and advice on the formulation of technical specifications, the choice of solution principles and the development of tender and project documentation which forms the contractual basis for ensuing construction activities.
We draw on a wide range of skills and are experts in core engineering disciplines such as structural, HVAC and electrical engineering coupled with construction management and owner representative services. Furthermore, we offer specialist services in areas such as tender management, building automation, indoor climate, building physics, material science and engineering as well as fire engineering.
Our ambition is to always be innovative and deliver projects and results which create value for our customers, ALECTIA and the society we are part of.
Our environment, energy, water and climate solutions are always based on sustainable consultancy. For instance, we advise the industry on energy and CO2 reduction and compliance with environmental requirements, and we are leading within cooling solutions for process and industrial companies as well as hospitals.
We combine the newest technology with years of experience when advising on water at all stages, from nature protection and soil and groundwater contamination to wastewater management and drinking water distribution. We advise during all project phases, from clarification, analysis, design and planning to tender, construction management and supervision.
In the climate area, increasing greenhouse gas emissions have caused climate changes which pose still greater challenges. Heavy rain incidents lead to rainwater and wastewater floods which cause traffic problems and damage to residences, businesses and plants. Combined with worn-down wastewater systems this increases the need for investments in new climate adaptation solutions. ALECTIA’s experts can help with planning and executing all kinds of climate projects, always going for viable long-term solutions to reducing greenhouse gas emissions and remediyng the damaging consequences.
Our clients are utility companies, local governments, the state and large Danish and international process and industrial companies.
In ALECTIA, we validate your chill and storage rooms with a specific temperature mapping procedure. By means of detailed CFD calculations, our experts can identify the air and temperature conditions in your chill rooms and storages including hot and cold spots. We help you to avoid energy waste and at the same time meet the legal temperature requirements.
Regular control of the room conditions is particularly important to companies producing and processing food. As an experienced adviser, ALECTIA has the equipment to perform detailed and accurate room tests, and our experts have extensive knowledge and many years of experience in establishing and regularly servicing production facilities for the food industry.
Legal requirements for storage temperature
ALECTIA has a comprehensive insight of the legal requirements and specifications applying to the food industry. We can confirm through specific tests whether your chill and storage rooms comply with the regulatory requirements. Furthermore, we can provide advice on how to optimize your storage energy consumption and your business, and make sure that you do not spent disproportionate resources on maintaining the correct temperature in your storage.
How we do it
Our consultants in ALECTIA initiate the validation process by identifying your specific needs and demands. On the basis of this, we prepare protocols for how to comply with the demands in practice. Subsequently, we prepare test plans in order to document that all tests proceed properly. Finally, we deliver a report of the test results with a conclusion of whether the requirements are met as well as a proposal for future actions.
When validating storages for the food industry, it is often very important to demonstrate that legal requirements for the temperature conditions are met. Therefore, we carry out temperature mapping by measuring the room temperatures over a period of time where several thermometers – the so-called temperature loggers – are placed on the basis of a risk assessment considering the hot and cold spots in the storage.
Temperature mapping with the CFD model
Earlier this year, ALECTIA prepared a cold storage validation with focus on ventilation design and air distribution. In this storage the air was distributed through a perforated ceiling, which made it difficult to calculate the temperature distribution. On the basis of the CFD calculations we worked out a 3D model providing a detailed insight into the heat and cold distribution of the storage, making it possible to identify the cold and hot spots.
By using the CFD model we were able to demonstrate that the temperature requirement of 3-8ºC could be met by setting the injection temperature at 3.5ºC and maintaining an air flow of minimum 50% of the maximum capacity. By knowing exactly what is needed to maintain the correct temperature, the client now reduces the risk of having too high temperatures. At the same time, the risk of energy waste is reduced as the exact amount of energy necessary to maintain the correct temperature conditions can be used.
Prior to the actual construction phase, all contractors were gathered for a statutory start-up meeting outlining Tican’s intentions and guidelines, including a Health & Safety Plan and the construction site design. At the meeting Tican invited to an open dialogue about the occupational health and safety work during the construction period with a view to making the contractors on site feel a sense of ownership and joint responsibility for maintaining a high level of order and safety.
“In our opinion, the focus on occupational health and safety is a precondition for implementing such a project. This view has characterized our and ALECTIA’s approach to the project, and the framework has been intelligible to the suppliers – to the benefit of the occupational health and safety on the construction site,” Tican’s Supply Chain Director Henrik Kæmpe said. “It is no secret that I am very proud of the occupational health and safety work performed in this project!”
Health and safety coordination on site
ALECTIA was responsible for the statutory occupational health and safety coordination during the construction phase, where inspection rounds were carried out on site and safety meetings were held every second week. Furthermore, ALECTIA’s health and safety coordinator and Ticans health and safety representative kept frequent dialogues on the different problems on site and possible solutions to them.
In the intervening period, Tican’s health and safety representative visited the site every day to communicate about safety and behaviour and signal Tican’s prioritisation of occupational health and safety. Similarly, regular introduction meetings were held for newly arrived workmen. As a result of this continuous and persistent focus on the construction site safety, only one minor accident occurred during the six month construction period.
Focus on safety in the project planning phase
The slaughterhouse Tican A/S is located at Thisted harbour (Denmark) where there is little space for a construction project with everything that goes along with it. Therefore, keeping focus on the construction site design and on particularly hazardous work already in the project planning phase was important in order to prevent accidents, and ALECTIA and Tican went through all the dangerous conditions that could be foreseen.
One issue concerned lifts close to the ammonia plant during panel mounting works at a compressor room. The solution was to empty the plant of ammonia in the area concerned and close off the crane area or set up watchmen and surveillance depending on the crane position. Moreover, the buildings, over which the crane lifted the panels, were evacuated.
Another problem was to allocate space for the workmen’s vans in the area. After a thorough assessment of where the expected number of cars in the construction period could be parked, the contractors were assigned parking spaces by means of the construction site drawing and an information leaflet.
The above-mentioned issues are just two of many conditions that were integrated already in the project planning phase, resulting in higher orderliness and tidiness and a more safe construction site. Moreover, taking preventive measures in the project planning phase has made the safety work much easier for Tican’s health and safety representative and ALECTIA’s health and safety coordinator in the construction phase.
Example from the parking leaflet: “The parking spaces at the construction site fence and the main entrance are ONLY for loading and unloading, which must only take place for 30 minutes at a time. This rule MUST be observed as there are a lot of vehicles in the area during the construction work. Long-term parking must take place in the public parking area at the harbour or in Tican’s parking place east of the slaughterhouse.”
Reducing accidents and absenteeism
For years, Danish Crown has focused on reducing the number of work accidents in their factories, and they are well advanced in their efforts. In 2007 they were rewarded with the Danish Working Environment Award for reducing the number of accidents by 50%.
Now Danish Crown has set up new goals for 2013-2018: The company wants to reduce the number of work accidents by a further 20% and at the same time reduce employee absenteeism due to work-related accidents by 30%. For this purpose, Danish Crown has contacted ALECTIA which has extensive experience within accident prevention and has implemented a targeted training course for mid-level managers with visible results.
Training course for mid-level managers
In order to achieve the ambitious goal, all mid-level managers in the entire group – i.e. the pork and beef divisions and Tulip – participated in a 2-day training course with particular focus on changing the existing safety culture. The training has put focus on roles and responsibility, employee involvement, communication, visualisation, working economy, clarification of consequences and tools for preventing accidents more efficiently, which are all prerequisites for the success of reducing the number of accidents.
“The training course has been shaped by experiences from the industry and consists of a combination of presentations, group work and penetrating discussions. The course makes demands on the mid-level managers who have to make home assignments during and after the training course,” project manager Ole Ryssel Rasmussen from ALECTIA said. “It is exactly this obligation and the continuous focus of the management that pay off. In that way, the competence development initiative becomes a good investment with a short payback time through increased awareness and fewer accidents.”
Remarks from the occupational health and safety manager at Danish Crown
On the question of whether training is the way forward, Danish Crown’s occupational health and safety manager Randi Madsen said:
“The mid-level manager training has been a great success in several areas and levels. The goal with the training has been achieved and the mid-level managers have obtained an improved understanding of the important role they play in terms of reducing the number of accidents, as well as how much they affect the employees as role models.”
“The mid-level managers have implemented large and small prevention projects, many of which have already had visible effects, and new projects are on the way – all of it inspired by this training course. The management has participated actively and visibly supported their mid-level managers and the many projects, and frequent management follow-ups have been implemented at the factories.”
“The training has had such great effect because it has been organized and composed in close cooperation between Danish Crown and a skilled team from ALECTIA. The training was carried out with high commitment and was targeted 100% at the target group. The follow-up with the participants during the training course has been very close, not least in connection with the large home assignments. The training has already had a great and visible effect that can be measured in terms of fewer accidents.”
Would you like to know more? Contact ALECTIA – Denmark’s largest authorized occupational health and safety adviser.
Through most of the 1900s, all animals for slaughter had to pass through the Meatpacking District of Copenhagen where they were checked by veterinarians, slaughtered and cut up before being distributed to the butchers in Copenhagen. Today, the Meatpacking District has developed into a cultural centre with galleries, restaurants, clubs, bars, schools and other creative companies. The renters still include companies which produce and sell food, and the need for cooling and freezing remains – now also for purposes such as comfort cooling, server cooling, etc.
The White Meatpacking District, which is located next to the older Brown Meatpacking District, opened in 1934. The place was equipped with a refrigeration plant which was ultramodern at the time and allowed for safe and hygienic handling and storage of carcasses and meat. However, as the existing refrigeration plant uses ammonia as refrigerant, which poses a toxic risk to the surroundings in case of ammonia emissions, an extensive environment protection project is in progress.
Copenhagen Properties put the project, with a budget of DKK 49 million, out for tender in a competition won by ALECTIA in 2013. It is a project in which our cross-disciplinary competencies are truly put to use.
“It is an exciting task with the particular challenge that the White Meatpacking District is totally preserved,” Project Manager in ALECTIA Claus Lund Poulsen explained. “It means that there are certain requirements for the appearance of some of the building services in terms of design and colour in order to maintain the original aesthetic expression.”
Ammonia replaced with glycol
The Municipality of Copenhagen’s Centre for Environment has issued an enforcement notice that the refrigeration plant in the Meatpacking District must be rebuilt to reduce the risk of ammonia emissions in case of an accident. A number of specific conditions relating to the refrigeration plant and the technical supply section in the Meatpacking District must be remedied before the end of 2014 for the Meatpacking District to remain open.
Ammonia has been widely used as a refrigerant because of its thermodynamic properties. However, it is also associated with great risks, as ammonia is highly poisonous to humans and nature.
The refrigeration plant will therefore be rebuilt so that the use of ammonia is limited to the distribution tunnels underneath the Meatpacking District as well as the actual technical supply section. In those parts of the cooling system, which are the responsibility of the renters, ammonia is replaced with glycol and water which are not equally dangerous.
ALECTIA facilitates all project phases
ALECTIA manages project design, tender documents, contracting and communication with all stakeholders as well as the general project management. During the implementation phase we are furthermore responsible for technical inspection, construction management, safety management and authorities processing.
For the rebuilding project, ALECTIA draws on a wide range of special competencies across our divisions. About 12 specialists are attached to different projects and contribute expertise including:
The refrigeration plant rebuild is currently well underway, and the works are divided between two contractors.
Copenhagen Meatpacking District anno 1930.
Miratorg’s factory in Kaliningrad produces hamburgers, nuggets, lasagna etc. to the Russian market. The production capacity per hour is 10 tonnes of finished products, which are frozen, packaged and sold in large batches to supermarkets and fastfood chains.
After a factory built in 2008 burned down in 2010, Miratorg started over again with the construction of a new food factory in Kaliningrad. ALECTIA was involved in the project from start to finish.
ALECTIA responsible for all process equipment
With a budget of approx. EUR 30 million, the Miratorg and ALECTIA project team has been in charge of the planning, procurement and installation of all process equipment for the new factory. This involved planning the layout of individual production lines and preparing requirement specifications for equipment suppliers. ALECTIA has also been responsible for tendering and tender evaluation and participated in the contract negotiations, followed by supervision of deliveries, installation and testing of the production equipment. At the end of 2012, the factory was ready for daily operation as one of the biggest food plants of its kind in Russia.
Miratorg selected ALECTIA to get facilities with quality standards which can be approved by the EU, with a view to future export possibilities.
“The client is happy with the new factory, which meets their requirements to quality, production capacity, etc. The factory is operating very well today,” said Senior Adviser Knud Rasmussen.
Additional projects for Miratorg
Since the completion of the project in Kaliningrad, ALECTIA has won more projects for Miratorg including the construction of a cattle slaughterhouse, a poultry slaughterhouse and two plants for packaged fresh meat.
At 11.00 h on Wednesday 12 November at the Nuremberg Messe, room Neu Delhi, Level 3, NCC Ost, it will be our great pleasure to present to you insights into:
• The ALECTIA Brewing Benchmark Club’s perspective on the beer industry’s performance in 2013, and how an audit can improve your business
• How ALECTIA Competitive Tendering and ALECTIA Project Management provides the best value CAPEX solution
• How ALECTIA Project Implementation, delivered from ALECTIA UK, can be the solution for your project needs
After the seminar, a light standing luncheon will be served.
To book attendance to the ALECTIA seminar, or book a meeting with our representatives at our stand, please contact Mrs Jytte Olsen, firstname.lastname@example.org.
ALECTIA will be present throughout the Brau Beviale 2014 at our bespoke stand, where it will be our pleasure to treat our clients to our homemade beer. At the same time, you will have the opportunity to discuss how to achieve the best solutions to your challenges with the best advisers in the industry.
You can also join our ALECTIA Brewing Benchmark Club at no cost, to start tracking your performance against your peers on a yearly basis.
T: +45 88 191 000
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