When Fairfield Dairy in Howick West decided to expand its yoghurt processing capacity by more than 2.5 times, the project required Reef Rigging to complete a technically complex series of silo exchanges and yoghurt buffer tank replacements — combining external crane operations with precision internal lifts through a roof opening. Here is how this multi-phase dairy capacity expansion was executed.
Project Overview: Fairfield Dairy Capacity Expansion
Fairfield Dairy’s expansion programme required changing out two 30,000-litre raw milk silos for two new 80,000-litre units — more than doubling raw milk storage capacity. Simultaneously, larger yoghurt buffer tanks in the processing facility had to be removed through the building’s roof opening and replaced with new higher-capacity units. The project was divided into two distinct phases, each with its own access requirements, equipment, and sequencing.
Phase 1: External Silo Exchange
The first phase — receiving and offloading the new 80,000-litre raw milk silos from incoming transporters — was completed in a single day using two crane trucks operating in tandem. The tandem lift approach was used to safely handle the large stainless steel silos without the risk of overloading a single crane. The silos were received and placed in a temporary lay-down area before being repositioned to their final external foundation pads. The existing 30,000-litre silos were removed from their pads and placed ready for collection by the seller.
Phase 2: Internal Yoghurt Buffer Tank Replacement Through the Roof
The second phase was more technically demanding. The yoghurt buffer tanks inside the production area were too large to exit through the building’s access doors — the only practical access was through the roof. A section of roof sheeting was removed to create the required opening. The existing tanks were then removed through the opening by mobile crane, and the new replacement tanks were craned in through the same opening and positioned in the production area. Working through a roof opening requires precise crane positioning and careful banksman coordination to manage the load through the restricted opening without contact with the building structure.
Project Outcome
Both phases were completed successfully, with Fairfield Dairy’s raw milk storage and yoghurt processing capacity expanded by more than 2.5 times. The project was a strong example of Reef Rigging’s ability to plan and execute complex multi-phase dairy expansion projects that combine external cranage with precision internal operations in a food-safe environment.
For dairy facility expansion and silo installation services, explore Reef Rigging’s food and dairy services or contact the team.
Frequently Asked Questions: Dairy Silo Installation and Expansion
Why are large dairy silos removed and replaced through the roof?
Large dairy silos are often installed inside buildings to protect their contents from temperature extremes, contamination, and weather. Once installed, these silos — particularly those over 30,000 litres — are typically too large to exit through the building’s side access doors. The practical solution is to open a section of the roof, providing the crane with direct access to lift the vessel vertically out of the building. The roof is then reinstated after the exchange is complete.
How do you prevent food contamination during a silo installation in a dairy facility?
Preventing food contamination during a dairy silo installation requires careful planning of the work zone relative to active processing areas, the use of appropriate covers and barriers to prevent dust, debris, or rigging equipment from contacting food contact surfaces, hygiene-compliant rigging equipment and materials in areas that contact the stainless steel vessel surfaces, and scheduling the installation work to occur when adjacent processing is not running where possible. The rigging team should follow the facility’s hygiene induction and entry protocols throughout their time on site.