The Challenge:

When leading yoghurt brand Müller needed to double production of its site near Telford to meet increasing demand, it turned to us for an extension to its plant which would double the size of the existing site.

It was crucial to the Müller client team that the existing factory and yoghurt production was not disrupted by the construction works. The challenge was to undertake this 5,700 sq m extension whilst ensuring the existing plant continued day-to-day production unaffected by our works.

The Solution:

Kier came up with a detailed logistics strategy which formed part of our winning tender bid to ensure the plant remained operational throughout.

The extension was attached to the rear of the existing building on an undeveloped section of the site. The project saw the installation of new packing and filling equipment and construction of a steel frame, temperature-controlled building to accommodate a high-speed pallet handling system.

Works were meticulously planned over two phases so as not to impact on the plant. The new ‘Goods Out’ facility was constructed as part of the phase one works, so that this facility could be relocated from its current position. This enabled phase two to be undertaken and connect the new extension to the existing plant. Kier designed innovative solutions that maintained key access dates for Müller’s new facilities, and maintained their production programme. Continued collaboration with the client and their design team ensured design changes resulting in additional programme time were mitigated.

The Impact:

‘Business as usual’ operations were maintained for the client throughout the build, with the extension works delivered without any delay to the live production facilities. Müller was very happy with Kier’s management of the project, with client satisfaction scores for the project being consistent at 9/10 throughout the project.

The extension allowed Müller to more than double their production of yoghurt at the Donnington Wood facility, whilst creating 65 new jobs in the local area. Kier were retained by Müller beyond our original completion date to provide safety management and control for the client to ensure the safety record was maintained.

The extension at Müller enhanced the site to become one of the most technologically advanced dairy production facilities in Europe.

The team achieved an exemplary safety record with no RIDDORS, operating adjacent to the live extended factory restricted logistics, loading and pedestrians were present 24 hours a day. Peaking at 160 site personnel, the site team achieved 99,540 accident-free man hours, with no accidents recorded throughout the project. An ethos of collaboration between the supply chain, client and Kier assured safety of all personnel.

Over this 54-week project we achieved high standards of safety and Considerate Constructor Scheme (CCS) scores, delivering a well-ordered quality factory extension.


" The great news for me is through close cooperation between our teams, there has been no interruption to factory operations throughout the build process. I know you have put a lot of effort into delivering a building on time and ensuring our operational requirements were met. "
Stuart Ellison Head of Engineering Müller Yoghurt & Desserts

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