Expansion of food production facility capacity with 810 m³

How Polem expanded production capacity in Poland by 810 m³ and enabled sustainable growth

Recently, Polem, in collaboration with Technology Unlimited, had the opportunity to realize a progressive project in Poland: the delivery of nine state-of-the-art flour and meal silos for a leading food producer.

The goal? To structurally increase the client's production capacity and improve the efficiency and sustainability of the production process.

Read more about opportunities in the food industry in our white paper.

Challenges and analysis

The client in Poland was dealing with growing market demand and outdated storage infrastructure. This created several bottlenecks:

Capacity shortage: insufficient storage space led to unnecessary production interruptions and delays.
Inefficient internal transport: limited silo capacity required frequent filling and transfer operations.
Strict food safety standards: the existing silos no longer met the latest European guidelines for food-grade applications.

A thorough analysis clearly identified these underlying problems and formed the basis for an appropriate solution.

Solution and implementation

Together with Technology Unlimited, Polem developed a custom solution: delivery of nine new, high-quality composite silos, distributed across three different orders.

Silo specifications:

Diameter: 3.5 meters
Storage capacity per silo: 90 m³
Total capacity: 810 m³
Food-grade finish: fully compliant with the strictest food safety standards
Material: lightweight and low-maintenance composite

The implementation process proceeded in phases:

Detailed project preparation in close coordination with the client and Technology Unlimited
Phased production and delivery of the silos from the Netherlands to Poland
Local assembly and integration into existing infrastructure
Thorough quality and safety inspection prior to commissioning

Flexibility in planning and close cooperation between all parties were crucial to guarantee a flawless result.

Results

The results speak for themselves:

810 m³ additional storage capacity, allowing production peaks to be easily managed

More efficient production process with less downtime and optimization of internal logistics

Lower operational costs due to fewer transfer movements and maintenance

Improved food safety, creating more confidence among customers and consumers

Increased sustainability thanks to the use of maintenance-free and energy-efficient composite materials

The project was delivered within the set deadline and to the full satisfaction of the client.

Lessons Learned

Key insights from this project:

Preliminary phase crucial: extensive upfront analysis delivers solutions that truly align with practice

Collaboration pays off: through synergy between Polem and Technology Unlimited, the entire process ran smoothly and efficiently

Customization makes the difference: no standard solution would have delivered this level of results

Flexibility in delivery: phased orders provided maximum room for client planning

Conclusion

With this project, Polem once again proves its value as a partner for sustainable and innovative storage solutions. Thanks to the new silos, the client in Poland can increase production capacity, work more efficiently, and comply with the strictest food safety standards.

This project also provides valuable insights for future international cooperation in the food industry.

FAQ

What makes Polem's composite silos so special?The silos are manufactured from high-quality, lightweight composite material. This makes them extremely durable, low-maintenance, and ideal for applications where food safety is crucial.
Why was a phased delivery of three orders chosen? A phased approach offered the client maximum flexibility in planning and limited the impact on ongoing production processes. This prevented factory downtime.
Are these silos suitable for food products other than flour and meal?Absolutely. The food-grade finish and design make them suitable for a wide range of dry food products, such as sugar, starch, and milk powder.
How does this project contribute to sustainability? Through the use of low-maintenance materials, the CO2 footprint is reduced in the long term. Additionally, the higher storage capacity helps reduce transport and transfer movements.
How long did the entire project take from design to delivery? From design through delivery and commissioning, the project took approximately six months. Through good cooperation, the lead time could remain short and manageable.