Project overview:
Airmatic Ltd was appointed by Purevent to manufacture and supply a bespoke stainless steel ductwork package for Kraft Heinz during a critical production shutdown. With manufacturing operations offline, the project carried significant time pressures, requiring rapid design development, fabrication and delivery to minimise downtime.
Despite multiple design revisions throughout the project, Airmatic successfully delivered the complete package within the client’s demanding four-week programme while remaining within budget.
The project demonstrated Airmatic’s ability to respond quickly to changing client requirements without compromising quality, communication or delivery performance.
The scope included:
The package consisted of a complete stainless steel ductwork system incorporating both round and rectangular ductwork components, including:
• Straight duct sections
• Bends
• Tapers
• Square-to-round transitions
• Plenum boxes
• Access doors
• Dampers
• Fully welded flanged sections
Airmatic also produced a comprehensive set of installation drawings to support the client’s on-site installation team, ensuring a smooth and efficient installation process.
Technical Specifications
Material: 316 Grade Stainless Steel
Rectangular Ductwork:
• 1.5mm stainless steel
Round Ductwork:
• Stainless metric pipe
Construction:
• Fully welded where applicable
• 5mm flat bar flanges
• Mill finish with welds left as laid
Standard Components:
• Access doors
• Dampers supplied as standard non-welded components
The project excluded:
• Specialist welding procedures or certification
• Specialist cleaning processes
• Delivery beyond agreed scope
• Additional unlisted items
• Leak-proof dampers or upgraded components
Engineering & Manufacturing Approach
The greatest challenge on this project was the exceptionally short delivery programme.
With only four weeks available from order to delivery, Airmatic structured the programme into three manufacturing phases, allocating one week to each ductwork section for:
• Production drawings
• Material procurement
• Fabrication
The final week was reserved for delivery, providing the installation contractor with sufficient time to complete installation during the shutdown period.
Throughout the programme, multiple client design revisions were incorporated without impacting the agreed completion date, demonstrating the flexibility of Airmatic’s engineering and production teams.
Technical hurdles we faced and the solutions we provided:
• Extremely tight four-week project programme
• Multiple design changes during manufacture
• Production shutdown requiring strict delivery deadlines
• Coordinating procurement, drawing production and fabrication simultaneously
The Solution
By maintaining close communication between the design office, procurement team and workshop, Airmatic was able to adapt quickly to changing requirements while maintaining programme certainty.
Detailed installation drawings reduced installation risks on site, while careful planning ensured materials were procured and fabrication commenced without delay.
The result was a streamlined manufacturing process that successfully met the client’s programme without compromising fabrication quality.
Benefits for the client
The project was delivered successfully, receiving excellent feedback from Purevent and the end client.
The successful outcome strengthened Airmatic’s relationship with Purevent, generating further opportunities for future work and reinforcing confidence in Airmatic’s ability to deliver under demanding programme constraints.
How this project has impacted Airmatic
The project reinforced several important principles for future fast-track contracts:
• Invest additional time in early planning and defining project requirements.
• Maintain strong communication between design, procurement and manufacturing teams.
• Set realistic internal milestones to protect delivery dates.
• Encourage collaboration across departments throughout the project lifecycle.
• Capture lessons learned continuously rather than only at project completion.
Conclusion
The successful delivery of the Kraft Heinz project highlights Airmatic’s capability to deliver high-quality stainless steel ductwork packages within extremely challenging timescales.
By combining responsive project management, flexible manufacturing and precision fabrication, Airmatic helped minimise production downtime while delivering a reliable solution for a demanding food manufacturing environment.
Airmatic delivered exactly what was needed under extremely challenging timescales. Despite several design changes throughout the project, their team remained responsive, professional and committed to meeting our programme. The ductwork package was delivered on time, the quality of fabrication was excellent and the installation drawings greatly assisted our team on site. We look forward to working with Airmatic again on any future projects.