In large-scale food manufacturing facilities, refrigeration is not simply about keeping products cold. Different ingredients require dedicated storage environments to maintain product quality, improve food safety, support production efficiency, and comply with strict hygiene standards. Separating dairy products from meat products is an important part of modern food manufacturing, reducing the risk of cross-contamination while improving inventory management and workflow.
Installing new refrigeration rooms inside a fully operational food production facility presents challenges that go far beyond construction. Production schedules cannot be interrupted, existing refrigeration systems must continue operating without disruption, and installation teams must work around ongoing manufacturing activities while maintaining the highest standards of workmanship and safety.
This case study demonstrates how Glotech Group successfully designed and installed two purpose-built cold rooms for Food Directions at its production facility in Airport Industria, Cape Town. The project included a dedicated dairy cold room and a dedicated butchery cold room, both completed while the manufacturing plant remained fully operational.
By carefully coordinating night-shift installations and responding to refrigeration breakdowns on the client’s existing systems throughout the project, Glotech Group delivered a successful installation without disrupting production.
Food Directions has established itself as one of South Africa’s leading hospitality and airline catering businesses by combining culinary excellence with efficient production systems.
As production volumes increased, additional specialised cold storage became necessary.
Rather than relying on shared refrigeration facilities, the company wanted dedicated cold rooms designed specifically for dairy and butchery operations.
This would improve production flow while supporting food safety, stock management, and operational efficiency.
Modern food manufacturing facilities rarely depend on one large cold room.
Instead, products are separated according to their production requirements.
For this project, Glotech Group designed two independent refrigeration rooms.
The dairy cold room provides temperature-controlled storage for milk products, cheeses, creams, and other chilled ingredients used throughout production.
The butchery cold room provides dedicated chilled storage for meat products before preparation and processing.
Separating these operations improves workflow while helping maintain high hygiene standards throughout the manufacturing process.
Both cold rooms were constructed using 75mm fire-rated polystyrene insulated panels with Chromadek finishes.
These panels were selected because they provide:
The Chromadek finish provides a durable, professional appearance while meeting the demands of commercial food production.
Unlike many commercial refrigeration projects completed in empty buildings, this installation took place inside a fully operational manufacturing facility.
Food Directions continued producing food throughout the project.
To avoid interrupting daily operations, Glotech Group scheduled installation work after normal production hours.
Every evening, work commenced at approximately 6:00 pm and continued until 3:00 am.
Working overnight required careful planning, disciplined project management, and exceptional commitment from the installation team.
By the time production staff returned each morning, work areas had been cleaned and prepared for normal manufacturing activities.
The installation presented another challenge beyond the unusual working hours.
Food Directions operated more than fifteen refrigeration systems throughout the production facility.
During the sixteen-day installation programme, normal refrigeration servicing responsibilities continued.
Unexpected refrigeration faults occasionally developed within existing cold rooms and freezer rooms.
Whenever breakdowns occurred, Glotech Group technicians temporarily shifted focus to restore refrigeration services before continuing with the installation.
This required careful coordination between installation teams and service technicians.
Maintaining existing refrigeration while simultaneously constructing new facilities demonstrated Glotech Group’s ability to manage complex projects within live production environments.
The project included:
Every stage followed Glotech Group’s commercial refrigeration engineering standards.
Despite the demanding schedule and ongoing service requirements, both cold rooms were completed according to programme.
Most importantly, Food Directions continued manufacturing throughout the project.
The carefully planned night-shift installation allowed the business to expand its refrigeration infrastructure without sacrificing production capacity.
This type of project demonstrates the importance of experience, planning, and flexibility when working within operational food manufacturing facilities.
The completed project delivered:
Most importantly, Food Directions gained two purpose-built refrigeration rooms that support safer food handling, more efficient production, and continued business growth.
With more than 15 years of experience, Glotech Group designs, installs, upgrades, repairs, and maintains commercial refrigeration systems for food manufacturers, airline catering facilities, restaurants, pharmaceutical companies, seafood processors, butcheries, supermarkets, and industrial businesses throughout South Africa.
Our services include:
Every refrigeration project is engineered around the client’s production process, operational requirements, and future growth objectives.
The Food Directions dairy and butchery cold room project demonstrates Glotech Group’s ability to deliver complex refrigeration installations within demanding manufacturing environments.
By constructing two dedicated cold rooms while the facility remained fully operational, our team successfully balanced installation work, emergency service support, and strict production schedules without disrupting the client’s business.
This project reflects the adaptability, technical expertise, and project management capabilities that Glotech Group has developed over more than 15 years of commercial refrigeration experience.
For food manufacturers expanding production, improving food safety, or modernising refrigeration facilities, Glotech Group continues to deliver engineered refrigeration solutions that combine reliability, efficiency, and long-term operational value.
067 153 8332
info@glotechgroup.co.za
Gotech Group offers emergency repair, replacement and installation of industrial and commercial refrigeration units restoring efficient operations in Hermanus & across Western Cape.