RB Group improves production throughput and reduces waste and maintenance costs

Corrugated cardboard is a highly sought-after packaging material. The client’s facility is the only speciality sheet manufacturer within the UK, and this substantial investment project aligns with the client’s year-on-year growth strategy.

The first project involved installing a single-face corrugator, rewinder, and materials handling line, refurbishing and relocating an existing single-facer, and procuring and installing new equipment. The RB Group team provided engineering design support and project management services for:

• Extensive civil works
• New electrical tie-ins, and controls interfacing with the site’s planning and warehouse system
• Installation of a new global control system and the integration of a condensate recovery system to reduce energy consumption
• PUWER assessment of the installed plant was conducted, leading to necessary safety upgrades

Our team managed the seamless integration of the refurbished and new machinery to optimise operational efficiency, taking full responsibility for programme scheduling to ensure the project remained on track and within the £3.6M budget. We also included managing cost control, overseeing risk and change management, and providing stakeholders with regular progress updates throughout the project’s duration.

The second project was awarded based on the success of the first, with site work scheduled to begin at the plant in December 2024. Works include:

Replacement of the dry end of an existing corrugator with new components:

• a rotary shear
• pulling station
• slitter scorer
• high-speed cutoff

Integration of these new components with the existing wet end and stacker, which are supplied by different OEMs.

Key tasks include ensuring the layout accommodates all operational requirements without clash points, and upgrading control systems, electrical infrastructure, and safety systems, and integrating these with existing IT applications. RB Group will manage the overall programme, ensuring cost control within a £2M budget, and oversee risk management, change management, and stakeholder progress updates.

RB Group’s comprehensive engineering and project management services for the ‘paper to board’ transformation facility delivered impressive results. The project not only increased production throughput but also significantly reduced waste, maintenance costs, and energy consumption, enhancing overall operational efficiency and sustainability. Safety improvements, driven by a detailed PUWER assessment, further ensured a safer working environment.