Lakeland Dairies Milk intake Extension

The Lakeland Dairies Milk Intake Extension represents a complex, steel-led infrastructure project delivered within a live, high-output dairy facility. Tusker Construction Group was appointed to design, fabricate, and install critical structural and process-support steel elements while maintaining uninterrupted plant operations. Working under a fixed-price contract and winter programme, the project required precision, coordination, and full integration across all disciplines.

At the core of the project was the challenge of installing significant steel structures, including the intake canopy extension, silo support infrastructure, pipe bridge, and associated frameworks, within a constrained, fully operational environment. Tusker adopted a phased delivery and installation strategy, allowing fabricated steel elements to be introduced, lifted, and assembled in sequence, without impacting daily milk intake operations.

The success of the works relied on disciplined planning and continuous coordination. Daily engagement with Lakeland Dairies’ operations team and tanker drivers ensured lifting operations, access routes, and installation windows were aligned with live production. This real-time coordination allowed risks to be identified early and mitigated effectively, maintaining full operational continuity throughout the build.

A key differentiator was the integration of design, fabrication, and installation as one controlled process. Structural steelwork, pipe supports, and associated components were designed and fabricated offsite, ensuring high levels of accuracy, quality, and consistency. This approach reduced on-site construction time, minimised congestion within the live facility, and allowed for safer, more efficient installation.

Tusker’s in-house capabilities across steel fabrication, crane hire, haulage, and construction were central to delivery. The ability to manage lifting operations, transport, and installation internally ensured tight programme control and eliminated interface risks typically associated with multiple subcontractors. This “We Do It All” approach provided a seamless workflow from fabrication yard to final installation on site.

Safety remained a critical priority throughout all steel erection and installation phases. Careful lift planning, controlled access, and continuous oversight ensured that all works were completed without a single health and safety incident.

The completed steel structures form the backbone of a modernised intake facility, supporting increased processing capacity, improved traffic flow, and enhanced operational safety. The integration of structural and process steel elements has enabled a highly efficient, future-ready facility capable of meeting Lakeland Dairies’ growing production demands.

Delivered on time and within budget, this project showcases Tusker’s expertise in steel-led construction, demonstrating how complex structural installations can be successfully executed in live industrial environments through planning, innovation, and integrated delivery.