A brand-new factory building for the Lithuanian company KG Group was completed near Vilnius in the middle of 2016. KG Group’s daughter company Vilniaus Paukstynas operates a food processing plant for chicken products in this building. Vilniaus Paukstynas produces several food products under its own brand and as a subcontractor to other foreign companies. More than 90 per cent of the production of this new factory is exported from Lithuania.
"The most important criteria for the new factory were efficient production and the meeting of all hygiene and other food industry requirements. We decided to build a completely new type of factory to meet today’s needs. This is also an investment for the future,” says one of the project managers Edgaras Molis.
Edgars Molis is one of three people that represented the owner of the project. The task of this managing and planning group was to design and develop all the elements in the implementation of this new factory project: the building itself, technological equipment, construction materials, engineering building systems, methods and so on. Their responsibility was to create a state-of-the-art factory.
In addition to production, environment values and social responsibility were taken fully into account during the planning phase. The goal was to create a building that is energy efficient and has the minimum environmental impact.
A factory with new standards
The new factory is 120 metres long and 96 metres wide, and operates on three floors. It replaced an old production building on the same site – constructing a new building was a far more rational choice than renovating the existing one. The idea for the new factory was born as far back as 2011, and the project kicked off a couple of years later, in the middle of 2014. The entire project was completed in two years, from the design table to the realisation of an operational production unit.
The factory’s structural solutions were realised to ensure that they were safe for food processing. For instance, areas of high and low contamination risk are totally separated from each other, and the utility area is located outside the production zone.
Recent technology has also been taken into use in the building, and not just in the production process. The factory cleans the water that it uses itself, any energy created as part of the process is used for the heating and cooling of the building and hot water preparation, the roof’s membrane prevents the building from becoming too hot in the summer, and an on-site steam and thermal oil power plant provides heat and cooling – to give just a few examples.
“We have made this factory as modern as possible by implementing the latest technology of the very highest standard. The building can be used in any kind of industry – it is state of art,” says Edgaras Molis.
Panels for the walls and roof
The planning group studied different building materials and selected products and technology without the involvement of any third party. Only the best materials were selected. Ruukki’s sandwich panels were selected for the internal and external walls as well as for ceilings. Ruukki also delivered load-bearing sheets for the roofs.
The food processing industry has extremely strict hygiene regulations. In order to satisfy them, Ruukki’s sandwich panels were given a special coating for their inner surfaces. A wear-resistant surface is needed because the building is cleaned daily.
According to Edgaras Molis, Ruukki panels have the following advantages: they save energy thanks to their excellent insulation properties, they are easy to maintain and replace if damaged, and they are quick to install, thus keeping construction time to a minimum.
Towards a high-quality future
Delivery capacities and schedules were the qualities that led the customer to select Ruukki as a supplier. It was all to do with the speed of the work: between 600 and 800 square metres of panels were installed each day.
“I believe in Ruukki and its products. They provided us with design help and they acted in a very professional way throughout. I never had any concerns, not even once,” states Edgaras Molis.
Quality requirements were the major guiding light for the entire project. Edgaras Molis describes it as a technology project that took the future fully into account.
“This was a project that made me think in totally new ways. We have to take future generations into account in everything we do. This project became a new standard in construction.”