Astute engineering design delivers 60% reduction in transportation requirements
RB Plant was engaged as engineering consultants for this major paper recycling project that delivered significant cost savings and environmental benefits. The project achieved a 60% reduction in transportation requirements, leading to lower operational costs and a decreased carbon footprint.
The client operates a significant paper milling facility that processes returned newspaper print collected from over 50 depots throughout the UK. The objective of the project was to design a more reliable and efficient collection system at each depot for loading trailers ready for transporting paper back to the mill.
The existing method of collection was dated, and a more reliable collection method was required
RB Plant served as Engineering Consultants for the project, undertaking a range of key responsibilities, including:
- Surveying each site to assess the suitability for trailer operations
- Leading and approving all civil and design/drafting works
- Representing the client across approximately 50 depots nationwide
- Reviewing and approving sub-supplier design drawings
- Preparing and distributing Gantt charts to manage labour and equipment schedules across multiple sites
- Coordinating the preparation and distribution of Construction Phase Plan documents for each location
- Day-to-day coordination of this extensive multi-site project.
Smooth out impact of peak activity
Reduce the burden of ‘peak site activity’. Monday morning returns including all the Sunday supplements put a large strain on current methods and personnel.Automation
To minimise level of manual intervention where possible thereby reducing safety risks to personnelImproved reliability of collection/exchange
Leading to less wastage/rejects Reduce transport requirements Thereby improving sustainability and lowering Carbon footprintReplace aging/obsolete equipment
Some equipment more than 20 years old with many safety issuesStandardisation
Standardise the collection method across the depots minimising inconsistenciesScalability
To be scalable and adaptable as volumes changeWhile a standardised method was used to capitalise on synergies, as a multi-site project, each location presented distinct issues. Local site restrictions, including layout and building heights, required individual attention and a tailored approach. Each planning authority had its own specific criteria, adding complexity to the process. Coordinating installations to ensure that sites continued to operate effectively demanded meticulous timing and planning. Additionally, managing cultural changes and addressing concerns from those resistant or anxious about the transformation was crucial to the project’s success.
A streamlined and reliable collection system was installed across all 50+ client sites, with customised conveyor systems tailored to each site’s layout and trailer loading requirements. Civil works for the construction of concrete plinths for trailer parking and building apertures for conveyor exits were carried out, and a trailer system, with individual weather canopies to prevent rain and wind ingress during trailer loading, was completed to ensure smooth and efficient operations in all conditions.
The successful completion of this project resulted in substantial cost savings and environmental gains, including a 60% reduction in transportation needs. RB Plant’s innovative approach not only streamlined operations but also significantly lowered the carbon footprint, aligning with the client’s sustainability objectives. This project underscores the value of efficient engineering solutions in driving both economic and environmental benefits.
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