Case Study: Retractable Tunnels Create Flexible, Compliant Working Environment For Millenium Site Services

By Luke Hutchinson on Aug 13, 2026, 11:00:01 AM

The Challenge

When Millenium Site Services, based in Derby, approached Hutchinsons PVC Solutions, they had a very specific operational challenge. Their work involved shot blasting and repainting train carriages, processes that require controlled environments for both safety and quality. Traditionally, this type of work is carried out in fixed booths or enclosed areas, but that approach didn’t suit their operation and they needed something far more flexible.

Rather than being tied to static workspaces, the client wanted the ability to move their working environment around their facility. Different carriage sizes, changing project requirements and the need to maximise available space meant a fixed solution would limit efficiency.

At the same time, they still needed to meet compliance requirements for containment and safe working conditions. The question was how to create large, controlled environments that were both fully functional and completely mobile?

The Objective

The goal of the project was to design and deliver two large-scale, retractable enclosure systems that could support key operational processes while allowing maximum flexibility.

Specifically, the client required:

• A retractable spray booth for repainting train carriages
• A retractable enclosure for shot blasting operations
• A system that could be easily moved and repositioned within the facility
• Full containment to support compliance and safe working practices

In short, they needed a solution that combined the performance of a fixed structure with the adaptability of a mobile system.

The Approach

Hutchinsons PVC Solutions developed a bespoke solution centred around two retractable tunnel systems, each designed to meet the specific requirements of the client’s processes.

These were not standard installations. Due to the size of the train carriages, the tunnels needed to be exceptionally large and tall, while still maintaining full structural integrity and ease of movement.

To achieve this, the project required specialist design and engineering input. We developed custom metalwork to support the scale of the structures, ensuring that each tunnel could maintain its shape and stability while remaining fully retractable. This was a critical part of our solution, as it allowed the system to combine strength with flexibility.

The retractable design meant that each enclosure could be extended when in use, creating a fully contained working environment and then retracted when not required, freeing up valuable floor space.

Mobility was also a key consideration. Each tunnel was designed to move smoothly within the facility, allowing operators to position the enclosure exactly where it was needed. This removed the limitations associated with fixed booths and gave the client far greater control over how their workspace was used.

Throughout the design and installation process, our focus remained on delivering a system that worked seamlessly within the client’s existing operation.

The Outcome

The result was the successful installation of two large, mobile retractable tunnels, each tailored to its specific application. These systems transformed the way Millenium Site Services could carry out their work. Instead of adapting their processes to suit fixed environments, they now had environments that could adapt to their processes.

This delivered several key benefits:

• Operational efficiency improved significantly. The ability to move the enclosures directly to the work area reduced unnecessary handling and repositioning of train carriages, saving time and simplifying workflows.
  
  
• The flexibility of the system allowed the client to make better use of their available space. When the tunnels were not in use, they could be retracted, opening up the facility for other activities.
  
  
• The enclosed design supported improved compliance. By creating contained environments for both shot blasting and spraying, the systems helped manage dust, overspray, and other environmental factors, contributing to safer working conditions.
  
  
• The solution future-proofed the client’s operation. As project requirements change, the retractable tunnels can be repositioned and adapted without the need for further structural work. This gives the client the flexibility to respond quickly to new opportunities without being constrained by their facility layout.

A Smarter Way To Work

This project highlights the value of thinking beyond traditional fixed structures when designing industrial workspaces. In many environments, the challenge isn’t just creating the right conditions for a process, it’s doing so in a way that supports efficiency, flexibility, and long-term growth.

Retractable systems offer a practical solution to this challenge. They provide the containment and performance needed for demanding industrial processes, while allowing the workspace to remain dynamic and adaptable.

Looking Ahead

With the installation of these retractable tunnels, Millenium Site Services now has a more flexible, efficient, and compliant working environment. The ability to move, expand and retract their enclosures gives them a level of control that fixed systems simply cannot offer.

For us, the project demonstrates how our bespoke, flexible solutions can unlock new ways of working, even in the most demanding industrial settings.

Need a flexible solution for large-scale industrial processes? Hutchinsons designs and installs bespoke retractable systems that adapt to your operation. Get in touch to discuss your requirements.