A leading European Dairy Company approached us to support a critical challenge within their Westbury facility: significant and ongoing energy loss within a live food production environment.
The process areas involved operate continuously under strict hygiene and temperature controls. Any prolonged shutdown to install traditional insulation systems was simply not viable. The client needed a solution that would:
Reduce unnecessary energy loss
Be installed within a live production environment
Meet hygiene requirements
Work within severe spatial constraints
Deliver measurable and rapid energy savings
The site was experiencing substantial thermal energy loss across pipework and equipment within a high-care process hall.
Traditional insulation methods — such as mineral wool with stainless steel cladding — were ruled out due to:
❌ Inability to shut down operations
❌ Insufficient space for required insulation thickness
❌ Complex and disruptive installation process
❌ Hygiene and contamination risks in a live food environment
The client needed a non-invasive, high-performance solution that could be installed while production remained operational.
Working in partnership with ESI Technologies Group, we specified and installed TFit® Flex, a high-performance insulation system engineered for demanding process environments.
TFit® Flex provided the ideal solution because it:
Offers exceptional thermal performance at reduced thickness
Is flexible and adaptable to complex geometries
Can be installed safely in live operational areas
Minimises disruption to hygiene-sensitive zones
Provides long-term durability in high-care food environments
The reduced thickness capability was particularly critical, as space restrictions would not allow traditional insulation build-ups.
From just one area within the factory:
⚡ 2,444 MWh of energy saved per annum
📉 Significant reduction in unnecessary heat loss
♻ Improved operational efficiency
💷 Major cost savings and carbon reduction impact
Importantly, this initial area represents only 10% of the total high-care food process areas within the factory.
The scale of opportunity across the entire site is substantial.
Due to the success of the initial phase:
The installation is ongoing across additional areas
A full-site implementation is now under review
Deployment across other UK facilities is being considered
This project has demonstrated how innovative insulation solutions can deliver transformational results — even within complex, live food manufacturing environments.
The works were carefully phased to ensure:
Zero disruption to production
Compliance with food-grade hygiene standards
Minimal footprint and clean installation practices
Ongoing coordination with site operations teams
The installation is being delivered in stages, beginning with one defined process area to validate performance and savings.
