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  • Karro Foods

    Karro Foods

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  • Client Karro Foods
  • Location Cookstown
  • Duration 52 weeks
  • Completion May 2016
  • Value £3M

Karro Foods

Heron Bros secured this project through a 2-stage competitive tender process to provide a new GIFA 2815m2  chill extension for Karro Foods. The building was purpose-built to rapidly lower the temperature of pig carcass prior to processing. The pioneering food production facility was designed to give the end product a longer shelf-life and improve efficiencies. Karro remained live throughout and Heron Bros ensured that minimal disruption to the client’s day to day operations.

The specialist blast chill room had the capabilities of lowering the temperature to -45°C. The facility featured a stand-alone internal steel portal frame which was built to expand and contract with fluctuating temperatures, without affecting the building’s structure. The bespoke self-draining flooring was laid to falls while the walls and ceilings were made up of freezer panels.

The cold store featured refrigerated panels on the walls and ceilings and was designed to have a temperature between 0°C and 4°C.

This project also involved the construction of a stand-alone reception and entrance building. This building featured a reception area, bathroom facilities, lift, glass facade and curtain-walling. A covered walkway bridge was installed across the top of the factory into the existing office space.

An amenity block, split over three levels was included in the works. On the top floor there was admin and office space with a bridge to the existing admin suite. On the middle floor there was a separate bridge to the production factory along with male changing and shower facilities. On the ground floor there was female changing and shower facilities, a reception area and a switch room which controlled the chilled facilities. In the interest of hygiene, a one-way system was in place so that there was a separate entrance and exit from the production facility.

External works included roads, carparks, footpaths, security fencing and concrete yards. Heron Bros extended the electrical pit-base and installed an internal substation.

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Project Design

Concept Architect: Teague & Sally Architect: Teague & Sally Services Engineer: Semple McKillop Structural Engineer: Teague & Sally

Key Features

  • GIFA 2815m2
  • Live environment
  • Minimal Disruption to Client’s Operations
  • First of its kind Blast Chiller Facility which provides a greater shelf life to the end product.


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