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JWCI works on world’s largest fresh milk Dairy

Global Dairy Company Arla Foods is renowned for its craftsmanship and commitment to the environment. Its new £150m dairy facility is no exception to this rule and Staffordshire based Process Engineers JWCI were on site to help. 

The new super dairy at Aylesbury, commissioned to provide a strategic base to service customers in and around London, has the capacity to process up to one billion litres of fresh milk and will be zero carbon, ensuring its environmentally sound credentials. 

Arla Foods brands include Anchor, Lurpak, Cravendale, Apetina and Tickler and is the UK’s number one provider of butter and spreads with a £2 billion turnover.

The contract for the chemical distribution at the new 70 acre Aylesbury site was awarded to Ecolab GMBH. JWCI have worked with Ecolab UK for many years but had previously only worked on smaller scale projects for the German company. JWCI invited the project leaders from Ecolab GMBH to their offices in 2012 so they could meet the team and see how JWCI’s experience and skills could benefit the project.

Kerry Callear, Company Director said;
“It was important for us to prove our level of competence aswell as our ability to meet all timescales and manage efficiently. We knew we had the capability so we just wanted to show that to Ecolab GMBH from the outset.”

Having worked in the food industry for many years JWCI have built up an enviable reputation for their high standards of professionalism so the relationship with Ecolab GMBH and the Arla project developed from there. 

JWCI were first on site for Ecolab in January 2013 to organise the early stages of the project and by February were designated to undertake the whole mechanical installation within the chemical room and service corridors to provide connection points to two other firms joining the site the following month. The team consisting of JWCI, a second British firm and a company from Germany worked alongside each other to then complete all chemical distribution plant and pipework throughout the factory. JWCI were last to leave site having completed all services during commissioning in November 2013.

Work undertaken included positioning tanks, installing brackets and all pipework, fabricating and installing walkways, gantry and staircases. JWCI also supplied the majority of pipe and fittings for use on the site by the three teams. 

Image showing tanks, gantry and pipework installed at Arla Foods Dairy in Aylesbury.
One of the two completed tank installations with bespoke stainless steel gantry. 
JWCI were responsible for all new pipe work throughout the chemical room 
along with the gantry and equipment installations.

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Major Project for Ecolab by JWCI Ltd

JWCI ltd are pleased to have been awarded the contract for a major restructure and refit at the Northwich Cheshire site for the global leader in the hygiene industry, Ecolab.This prestigious contract was awarded to JWCI after the world’s largest sustainability services company, Nalco merged with hygiene giant Ecolab.  

The merger means Ecolab now have over 41,000 employees in more than 170 countries. Founded in 1923 the merger brings together two highly complimentary industries to provide global sustainability services and hygiene solutions across the food, beverage, hygiene and medical industries.

The joining of the two businesses saw the Ecolab manufacturing facility at Cheadle Hulme being relocated to join the larger Ecolab/Nalco site at Northwich in Cheshire. 

JWCI have worked on projects for Ecolab previously and proved to be highly competent in their professional manner and expertise both on site and in the design and manufacture stages. 

Rob Pettener from Ecolab UK said “JWCI proved to be a reliable and flexible contractor to EcoLab. JWCI are well known and respected within the industry and have clearly demonstrated a track record to deliver on large and complex installation projects.”

Phase one of this large project was undertaken by JWCI in partnership with Ecolab’s onsite team and  proved such a success that JWCI became solely responsible for Phase two.
Phase one of the contract, which began in December 2012 included supply and installation of pipe work, removal and installation of tanks and mixing vessels plus supply, fabrication and installation of new tailored pipework and mezzanine floor supports. The later phase involved the strip out of the new site which included provision and management of crane lifts and providing all required health and safety documentation surrounding this. JWCI provide a full design, manufacture, installation and maintenance service to their customers and this streamlined ‘one supplier’ approach means greater peace of mind for the client. 
The larger second phase, a complete strip out and replacement project, included decommissioning of existing mixer tanks and pipework plus installing new steam lines, steam traps, valves and instrumentation. New gantries and pipework were fabricated and installed by JWCI’s highly experienced on-site team.
JWCI work to the highest safety standards and are compliant to all current British health and Safety guidelines and best practice schemes. JWCI are proud to be ISO 9001 registered and SafeContractor accredited. They are also CHAS approved and registered with Constructionline to provide the highest standards whilst on-site. 
JWCI’s expertise in providing bespoke solutions tailored to their customers exact requirements meant that Ecolab could streamline their processes and improve efficiency and be assured of excellent workmanship. This coupled with the high level of customer service provided by JWCI meant a winning combination. 



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JWCI Centralised Cleaning Systems Overview

Centralised Cleaning systems designed and built to your requirements. We understand the importance of hygiene within the food industry, so can advise you on the best type of equipment to use, where there is not a suitable “off the shelf” solution we, design, build and install bespoke hygienic cleaning systems.


As standard we offer:

  • Free site visits to assess your needs 
  • Designed & installed to meet your production demand
  • Up to 30 users on one system
  • Pipe work & equipment installed & commissioned


Hygiene Cleaning Systems

JWCI will also design and manufacture bespoke pressure cleaning systems to suit a customer’s requirement.
These range from single wall mounted machine to larger multi-pump units for multi user wash down requirements. 
Larger water wash down requirements usually consist of a multi-pump which will be more energy efficient especially where there is a requirement for one or two operators most of the working day but at the end of a shift the cleaning is more intense requiring many more operators using the system simultaneously. This can be an efficient method to provide hot pressurized water via a ring main system to various points around a factory.
All of our central pressure systems can be used to apply foam chemicals and sanitizers, hot & cold water. For this we use a number of options ranging from a single foam venturi to a central chemical distribution system whereby the chemical is pumped to satellite dispensers installed in the factory. At these wash stations the foam and sanitizer can be selected and applied using the appropriate lance.

Types of Centralised Wash down systems

Both low pressure systems, medium pressure systems and high pressure systems are available or a combination of pressures can be accommodated by one pumping unit.
The correct cleaning pressure for each cleaning task can be determined by using our free factory survey. This will ensure that you get the most energy efficient, cost effective cleaning system for your factory.
We also place great importance on after sales service arrangements. This can be by means of a “pay as you receive” service plan, to a fully paid up annual maintenance plan, where one fee covers both service and breakdown visits.




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JWCI Ltd Process Engineers

COMPLETE SOLUTIONS: Design >>  Manufacture >>  Install >>  Manage 


JWCI Limited is a long established company, located in the heart of the UK with our Head Office in Cheadle and manufacturing facilities in Fole, Uttoxeter.
We design, construct and install processing equipment for a wide range of customers in the dairy, food, chemical and other process industries.

Along with the installation of plant and its associated pipe work we offer designing, fabricating and installation of staircases, walkways and other structural work.
The continued success of the company is based upon a strong commitment to our customers and to always deliver work to the highest standard.
We offer consultancy for design, supply and commissioning of complete plants or single items of equipment.
Our skilled engineers, technicians and fabricators have the expertise, resources and experience to ensure your process plant will deliver reliable and efficient manufacturing, and the installations are completed on time, within budget.
Our engineers can help develop innovative and efficient processes that will give you a competitive edge and provide years of trouble free manufacturing.
We utilise the latest technologies so you benefit from the knowledge we gain across many industries and applications.
We place our reputation on the quality of every job, large or small, ensuring your complete satisfaction.