Case Study : Food & Drink

Case Study 1

Leavening Agent Production

 

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

Case Study 2

Upgrade Of Wheat Starch Production to 21T/Hr

 

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