Fyffes Group Banana Ripening Rooms

The Requirements

Fyffes Group Limited had scope to enlarge and modernise their existing banana ripening facility and awarded MTX the design, supply and installation contract. Upon completion of the initial construction phase of the project, which included a 3750m² extension to the existing facility and once all the designs had been finalised, MTX were able to start work on the installation and commissioning of 36no 60 pallet ripening rooms.

The construction programme stipulated that the rooms were ‘to be handed over to the client on a uniquely phased basis throughout the construction period, enabling the client to relinquish existing rooms for decommissioning and removal’, with the aim of reducing disruption to staff and daily production schedules.

The Solution

To deliver this project, MTX devised a uniquely phased construction programme:

The 1^st phase of the construction programme involved the installation of rooms 1-16 in the newly extended part of the facility. These 16 rooms alone provided the client with the same ripening capacity as the 40 rooms originally in operation at the facility. MTX also installed a state of the art central chilled water plant, which involved complex installation works across the entire facility.

During the 2^nd phase of the project, rooms 17-20 were completed. These rooms provided our client with a total of 20no fully commissioned MTX ripening rooms after only 20 weeks after initial works commenced and increased the facility’s ripening capabilities from 960 to 1200 pallets (or 51,840 to 64,800 boxes).

In the 3^rd phase MTX developed the temperature controlled loading bays and a state of the art packing and production area. The final 16 rooms (rooms 21-36) were also installed and commissioned at this time.

The 4^th and final phase of this project saw the installation of 2 large melon and pineapple chill stores.

Main Considerations

The 2^nd phase of the project provided the most significant challenges for MTX as the old ripening rooms had to be decommissioned and removed alongside the main production and packing area, which remained in full operation throughout the entire construction programme. During this phase 4 rooms (rooms 17-20) were completed and successfully handed over.

An expertly phased construction programme and careful co-ordination between the core project team, allowed the client to successfully double their ripening capabilities in just 36 weeks, while maintaining all existing ripening and production commitments.