Flavours Foods Ltd, a sandwich filler factory based in Monk Bretton, approached IDL with a persistent issue affecting their stainless steel equipment. Their operations involve continuous exposure to water and chemicals, which had caused repeated weld failures on critical components. This challenge was compounded by the factory’s strict hygiene requirements, making it difficult to find welders able to work safely on site.
The challenge
During a free survey arranged by IDL, our engineer Adam was welcomed by Jonny, who guided the team through the hygiene protocols necessary to work in the factory environment. The main issues identified were:
- A broken side bar rail on a steriliser machine that separates two hygiene zones, with snapped brackets needing precise repair.
- Cracks forming on a large stainless steel tub used for food handling.
- A drooping stainless steel table lacking middle support, causing structural concerns.
The steriliser and tub were located in a hygiene-sensitive area and could not be moved. Welding in such an environment required careful planning to avoid contamination and maintain food safety standards.
Our approach
To minimise disruption and maintain hygiene, the welding of the steriliser’s side bar rail was scheduled to be done off-site. The hood was removed and transported to a clean area where the welding could be safely completed without risking contamination in the hygiene room.
The engineer arrived fully equipped with all necessary safety and welding gear, including welding screens, fire extinguishers, and air-fed helmets. Despite challenging weather conditions, cold, windy, and the risk of rain, the job was completed without incident, thanks to careful preparation and vigilance.
The repair involved fabricating new stainless steel brackets on-site using a grinder and steel sheets, as laser-cut parts were not feasible within the project timeline. Precision was critical to ensure the rail fit perfectly into the brackets and grooves, preventing future damage caused by cleaning processes.
The welding was performed with strong, visible welds to ensure durability, avoiding sanding down to maintain strength. The engineer also addressed a secondary issue with a trolley’s middle support bar, reinforcing it with robust welds after cleaning rust and old welds.
Outcome
Jonny was pleased with the quality and precision of the repairs, particularly appreciating the proactive identification of the table’s structural issue. The work was completed efficiently with minimal disruption to the factory’s operations.
IDL demonstrated not only technical skill but also an understanding of the client’s operational and hygiene needs, offering flexible scheduling options including overnight or weekend work to accommodate the factory’s constraints.
For businesses facing similar challenges with stainless steel weld repairs in demanding environments, IDL offers expert solutions tailored to your needs. Contact us to discuss how we can support your operations with reliable, high-quality welding and fabrication services.
