Gü partnered with RB to deliver the project which includes installing a new production line and packaging line into an existing facility which operates 24/7. This has to be achieved with just a few days downtime for the existing production facilities. This new packaging line will significantly increase the production capability of Gü as they continue to accelerate growth in the countries they sell in.
To achieve this RB have 3D scanned and modelled the entire site including all existing equipment, utilities and buildings. The new packaging line 3D model was then federated into the site model. This ensures the packaging line can be easily operated and maintained once installed. RB have overseen the partial relocation of the existing Gü packaging line to make space for the new high speed line. RB have worked closely with the packing line manufacturer to ensure the line can be constructed off site, fully tested and then installed with minimal disruption to the existing site production.
The entire line will be assembled and run at high speed during a full FAT and PUWER assessment at the OEM facility in Ireland. The line will then be carefully disassembled, shipped to the UK and installed at the Gü Bishops Stortford site.
The new packaging line includes the latest advanced technology and will enable Gü to continue to innovate and bring the most irresistible chilled treats to consumers around the world.
RB Director and Gü Line 2 Program Director Seán McKirdy would like to thank the entire team (Gü, RB and suppliers) for all of the hard work and success to date.
The following images show the progress to date at the OEM assembly hall in Ireland.
Summary
- LOCATION: Southern England
- INDUSTRY: Flavours/Food and drink
- PROJECT COST: £983K
- RBP FEES: £33K (Budget £45K)
- PROJECT DURATION: 5 months
Project brief
- Client had increased projected market demand however capacity of existing assets insufficient to meet this demand
- 2 x options investigated; a) re-use existing distillation equipment and b) buy new
Challenges and solutions
Challenge: Limited process design basis for existing bespoke processes
Solution proposed: Reverse engineered existing bespoke design using actual operating data
Challenge: Limited data on capacity of existing utility systems
Solution proposed: Assessed approximate Utilities systems capacities and project impact
Challenge: Ensure sufficient detail to differentiate between 2 options without exceeding budget
Solution proposed:
- Identified deliverables common to both options to avoid unnecessary duplication.
- Identified cost elements (e.g. electrical and civil common to both elements)
- Used cost data from similar previous projects, databases and vendors
- Identified high level risks and limitations of existing options
Challenge: Limited available footprint
Solution proposed: Rotated process “skid” through 90° to ensure no clash with roof trusses
Outcome and client benefits
- Option A – reusing existing still possible with extra design checks but with restricted throughput (2/3 x target)
- Option B - Cost estimate for new still system to ±20% accuracy suitable for Client to assess financial feasibility
- High level design suitable for rapid progression to FEED stage if/when required
- Came in significantly under budget - £33K compared to £45K
RB Plant Construction Ltd (RBPC) were instrumental in assisting Trewithen Dairy to upgrade a small family-run, farm-based dairy to a full-scale modern production facility employing over 200 people.
Trewithen Dairy produces 80m litres of milk annually to be sold in major supermarkets and stores across the South West. Trewithen Dairy also produces cream, yoghurt, and clotted cream for supermarkets and ice-cream production.
RBPC were integral in assisting Trewithen Dairy with all the major engineering and management activities associated with the £12m upgrade project across a period of 7 years.
The upgrade included:-
- RBPC were responsible for the design and management of the build of the upgraded production facilities and re-fit of existing buildings. This package of works included the design of the high care and low care production areas, changing facilities, laboratory, new creamery (including ovens and frezers for Clotted Cream production), milk bottling hall, packing facilities, cold storage, services plant room, HV and LV substations and switch rooms, and the lorry park and loading bay facilities.
- RBPC were responsible for the design and specification of the new production facilities, CIP, steam system and boilers, tankage, effluent and laboratory facilities, cold store, and bottling handling and filling.
- RBPC were responsible for the design and specification of the new electrical supply and distribution from overhead HV supply to field distribution. RBPC designed the entire system and oversaw the installation and commissioning, including all technical co-ordination with Western Power and equipment specifications.
- The entire project was co-funded by the SWRDA, and RBPC played a significant role in ensuring compliance with all grant authority requirements and applications.
SCOPE
RB Plant’s client, a global manufacturer and supplier of technical leavening agents, were experiencing increased demands in export markets. This identified a requirement for increased production and up sizing of the current facility. RB Plant were engaged to provide design for both relocation of existing equipment and expansion into existing buildings.
CHALLENGE
RB Plant have to date designed schemes based on this original scope and more recently new schemes as our client have subsequently committed to an additional building and a new build on the same site. We have had to be creative in our design to accommodate improved layouts of existing equipment as well as new installations over three identified phases of work.
OUTCOME
RB Plant have also supplied construction phase cost estimates to provide civil / structural, electrical, mechanical and HVAC engineering disciplines, detail design and project management, construction management, CDM and procurement services. Our client is proceeding on this basis
BENEFIT
RB Plant have satisfied all deliverables to date whilst processing changing scope demands and scheme options. RB Plant have provided consultancy services in excess of 650-man hours and are looking forward to moving on to the next phase of work. We have satisfied our client’s expectations and look forward to a continuing and mutually beneficial relationship
SCOPE
RB Plant’s client’s, project was to increase the capacity of the Mill & Starch manufacturing facility to 240000 tons of wheat grind/year with an annual operating capacity of 21t/hr of flour throughput . RB Plants initial role was to carry out a preliminary study to encompass:
- Detailed Process Schematics
- Process Layout
- Equipment & Line Capacities
- Numerical Catalogue of Project Tasks & activities
- Accurate Project Costs
- Project timescale & preliminary program
- Production Plan & Outage schedule
From the above RB plant was then tasked with the construction/installation of the plant & equipment to achieve the required processing improvement as listed below .
CHALLENGE
RB Plant main challenges were the following:
- Flour Mill
- Install additional Satake Debranning Technology to increase mill capacity to 21t/Hr
- Dough Preparation & Separation
- Install Flour Water mixer to Client’s standard
- Install Batter residence Loop
- Install Hydrocyclone separators to the Client’s “Pate Mole” standard
- Gluten Drying & Milling
- Up rate gluten dryer feed system
- Install additional gluten dewatering equipment
- Up rate gluten milling system with standard Client’s Freres Mill
- Up rate existing dryers
- Install intermediate Starch slurry storage
- Upgrade Finished Product Storage & out load
- Starch Refining Process
- Install additional fibre removal equipment to Client’s standard
- Replace current refining hydrocyclone system with Client’s standard
- Install QX separator equipment on secondary starch (A-) stream
- Soluble Process
- Pipe work to be reviewed
- De-Bottleneck solubles evaporation stage
- Utilities
- Replace the starch Provox system with Foxboro system
- Upgrade compressed air system
- Upgrade electrical distribution system
- Install additional boiler water treatment capacity
- Upgrade buildings & roads
All other work identified & defined by Pre-Project study
OUTCOME
RB Plant’s end result of all the works above was beneficial operation on time and within budget . Allowing for increase production capacity to begin on schedule.
BENEFIT
RB Plant ‘s main benefits to the client were through their increased processing capacity & plant throughput increase. Also, by updating their electrical & control systems better process control was achieved & reduced loses through better overall control of the plant