Russell WBHO completes Heywood logistics superhub

Russell WBHO has completed the final phase of works for Lineage Logistics at its UK headquarters in Heywood, Greater Manchester.

The main contractor has just handed over a new 70,000 sq ft temperature-controlled cold store with the capacity to hold 22,500 pallets, bringing the facility total to 78,000 pallets.

This final 12-month build was the completion of a three-phase extension to the global operator’s Heywood Superhub which Russell WBHO began in 2011. The first two phases completed in 2013 and comprised 100,000 sq ft of space and 28,000 pallets.

Lineage’s 20-acre site off Hareshill Road now boasts a total 425,000 sq ft of space providing consolidated storage for the UK’s major food manufacturing, food service and food retail brands.

The project saw the introduction of the new style single-skin cold store, now preferred over the traditional ‘box-in-box’ construction where the internal refrigerated chamber sits separately within the outer building. The use of single skin maximises internal area and thereby pallet space capacity.

The Russell WBHO team successfully linked the new building to the existing older design, with no compromise to the integrity of the minus 30-degree temperature during the construction programme or ongoing operation.

Strict carbon reduction targets have also been met, with state-of-the art materials and mechanical systems installed. The new facility will provide Lineage with a 75% operational energy cost saving when compared to the European energy consumption average, thanks to the installation of the award-winning Azanefreezer 2.0 system from Star Refrigeration.

The extension provides another eight double-height loading docks and a temperature-controlled loading area to ensure a secure cold chain for products as they enter the facility from the temperature-controlled lorries.

In linking the structures together, the team had to consider conflicting priorities between ensuring temperature integrity, dehumidification and reduction in energy use, and the ability to move seamlessly around the building and between chambers. This required careful design and the use of specialist products such as insulation and fast-closing door seals, and management of the construction work alongside that of the existing operational chamber.