Mezzanine storage platform

Mezzanine storage platforms at Britvic

Case Study : Mezzanine storage platforms

Intelect were contracted Britvic to undertake the design, fabrication and installation of a number of new mezzanines and gantries for their site in London.

This mezzanine was listed as number 1 and was free standing in the new section of the factory.

 

Project Information

Project: Mezzanine storage platforms
Client: Britvic
Sector: Food & Beverages
Discipline: Mechanical Design
Value: Various

Additional Information

Find out more about this project or the services we provided please contact a member of our team:

Teesside: 01642 878784

Humberside: 01472 344901

The Midlands: 01455 286071

Feasibility Study

Feasibility Study

Case Study : 800AMP LV Distribution Switchboard

Intelect were contracted by PPG to provide two 3D as-built models of Unit 1 and Unit 2.

The model was developed using point-cloud data captured via our Faro Focus 3D S70 Laser Scanner. Each unit of the factory was scanned over a period of four days including the external building which we provided the client with a hard copy of all scan data for future use.

The 3D models were then manipulated to provide 2D plans and elevations ensuring all new equipment and machinery fit within the working areas. We then introduced our pipework division to produce P&ID’s based on new layouts.

All machinery and equipment were provided via external customers, these included Dromont, Packland, Devree, Cimaco-solutions and more. This helped us achieve the best possible outcome to improve PPG’s current production rate.

Project Information

Project: Feasibility Study
Client: PPG Architectural Coatings UK Ltd
Sector: Paints, Coatings and Materials
Discipline: Point-cloud and 3D Modelling
Value: Various

Additional Information

Find out more about this project or the services we provided please contact a member of our team:

Teesside: 01642 878784

Humberside: 01472 344901

The Midlands: 01455 286071

Material Handling Platform

Project Pelican

Case Study : Project Pelican

Intelect were contracted by KP Snacks to provide a total turn-key solution for a large project.

Prior to the project commencing, members of Intelect’s Electrical and Mechanical team travelled to Germany to assess the equipment and running order of two lines in a different factory that we had been contracted to decommission and relocate to the UK.

The project aim was to install two full process lines for the client, for two of their most popular products. Each line and platform had its own task to achieve within this process, in order for the products to reach the packing hall to be packaged, boxed and shipped.

As well as overseeing the project from a lead CDM role, Intelect were also contracted by KP Snacks to design, fabricate and install a series of hygienic platforms in accordance to BSEN1090. The platform design was developed in collaboration with Daxner to ensure access to their machinery was achieved to the British Standards. The platforms were also built with a hygienic design in mind, to ensure that they were easy to clean and maintain.

The platforms produced during these works included:

  • Material Handling Platform
  • Big Bag Station Platform
  • Allergen Platform
  • Compressor Platform
  • Bespoke Line Platforms

The high standard of work carried out from the design through to the fabrication and installation were shown across each individual platform.

On average, around 30 Intelect employees, across range of capabilities, were working on the site at any one time, along with additional subcontractors, who we were also responsible for.

The entire project was completed to the highest standards and to the expectations of the client, who also complimented us for our management, supervision and support throughout the project.

Project Information

Project: Pelican
Client: KP Snacks
Sector: Food Manufacture
Discipline: Mechanical and Process Design, CDM Services
Value: Various

Additional Information

Find out more about this project or the services we provided please contact a member of our team:

Teesside: 01642 878784

Humberside: 01472 344901

The Midlands: 01455 286071

Tata Steel Drive Control Panel Refurbishment

Tata Steel Drive Control Panel Refurbishment

Case Study : Tata Steel Drive Control Panel Refurbishment

Intelect were contracted by GE Energy to complete the mechanical design, installation and refurbishment of an onsite Control System based at a Tata Steel site.

Following an engineering site survey, the installation of three replacement drive control systems was completed during a shutdown period of 4 days, in order to best suit the interests of the client.

The installation stage of the project consisted of replacing the obsolete drive with onsite copper work modifications, and upgrading the control PLC systems. Preparation work prior to the installation was completed in-house by our team of fully qualified engineers, and manufactured to the design drawings and specifications of the client.

The project was completed on schedule and within budget, ensuring complete client satisfaction.

Project Information

Project: Tata Steel Drive Control Panel Refurbishment
Client: GE Energy
Sector: Heavy Industry
Value: £50,000

Additional Information

Find out more about this project or the services we provided please contact a member of our team:

Teesside: 01642 878784

Humberside: 01472 344901

The Midlands: 01455 286071

Tea Blend Control System

Ringtons Tea Blend Control System

Case Study : Ringtons Tea Blend Control System

Intelect were contracted by Ringtons to provide a full turnkey solution from design through to commissioning, in order to replace three existing blend panels with on master panel.

The design and integration of the new Blend Control System was created in order to replace an obsolete control system. The new system is controlled via a Siemens PLC communicating with a Siemens HMI, in order to improve efficiency.

Major features of the project included:

  • Design and Build of New Blender Control Panel
  • System Software and Coding
  • Engineering Site Surveys
  • Non-Intrusive Preliminary Installation Works
  • New Blender Panel Installation
  • Commissioning
  • Removal of Redundant Electrical Equipment

The project was completed within a short time frame to accommodate the client’s production schedule, and to minimise downtime. Installation and commissioning of the system was completed over a weekend by our skilled installation engineers, with prior planning and preparations taking place in advance within our specialised Panel workshop.

Project Information

Project: Ringtons Tea Blend Control System
Client: Ringtons
Sector: Hot Beverage Manufacturing
Value: £60,000

Additional Information

Find out more about this project or the services we provided please contact a member of our team:

Teesside: 01642 878784

Humberside: 01472 344901

The Midlands: 01455 286071

Kolak Foods Air Handling Control System

Kolak Foods Air Handling Control System

Case Study : Kolak Foods Air Handling Control System

Kolak Foods requested our expertise to design and build a stainless-steel variable speed drive control panel, built to control air flow into a factory extension production area, via inlet and extractor fans.

Our team were given 4 weeks to complete the project, in order to minimise production down time for the client.

The design and assembly of the panel was completed in-house by our team of specialised engineers from our dedicated panel department.

The second stage of the project was completed on the client’s site by our electrical installation team, completing the install and commissioning of the project.

The client was fully supported by the management team from design through to commissioning, providing clarity and support at every stage of the process, which in turn was completed on time and within budgete.

Project Information

Project: Air Handling Control System
Client: Kolak Foods
Sector: Food Manufacturing
Value: £25,000

Additional Information

Find out more about this project or the services we provided please contact a member of our team:

Teesside: 01642 878784

Humberside: 01472 344901

The Midlands: 01455 286071

Corby Roller Table 200KW Replacement Drives

Corby Roller Table 200KW Replacement Drives

Case Study : Corby Roller Table 200KW Replacement Drives

Intelect were contracted by GE Energy to supply, manufacture and install a 200KW Drive Control Panel, to replace existing obsolete equipment on site at Tata Steel, Corby.

In order to minimise disruption to the client, the panels were deigned and arranged around existing cabling to complement the structure of the site.

A coordinated team of seven skilled engineers were involved at multiple stages throughout this project, both in-house and on the client’s site, ensuring that the client was supported at every stage of the process.

Works were carried out over a shutdown period of 4 days, to suit the client’s production agenda. Commissioning was completed ahead of schedule, and within budget, ensuring maximum efficiency.

Project Information

Corby Roller Table 200KW Replacement Drives
Client: GE Energy
Sector: Heavy Industry
Value: £80,000

Additional Information

Find out more about this project or the services we provided please contact a member of our team:

Teesside: 01642 878784

Humberside: 01472 344901

The Midlands: 01455 286071

Distribution switchboard

800AMP LV Distribution Switchboard

Case Study : 800AMP LV Distribution Switchboard

Working to the British Standard 61439, Intelect were contracted to design and commission a Form 4, Type 2, 800AMP Distribution Switchboard, to service supplies to an extension to the client’s current factory.

From the initial in-house design through to commissioning, the project was turned around in 6 weeks, with a team of 4 expert engineers working to tight deadlines throughout.

Our specialised team within the Panel Department ensured the client was fully supported throughout each stage of the project. This allowed for flexibility and maximum efficiency, which was vital in such a short time frame.

The project was installed and commissioned on time, at a high degree of quality, and in line with the necessary regulations.

Project Information

800AMP LV Distribution Switchboard
Client: PM Group
Sector: Multi-industry
Value: £45,000

Additional Information

Find out more about this project or the services we provided please contact a member of our team:

Teesside: 01642 878784

Humberside: 01472 344901

The Midlands: 01455 286071

KP Billingham

Intelect & KP Snacks, Teesside

News & Features

KP Billingham

Intelect and KP Snacks, Teesside

Intelect's John Henderson (Senior Electrical Supervisor) heads up the team of 5 electrical engineers who work on a long term contract at KP’s manufacturing plant on Teesside.

Intelect have been working at the plant since 2000, with John’s team permanently on site since 2005. Their role on the site is split between project, maintenance and repair work to both the production line and the building.

Working alongside KP’s own staff

The factory underwent substantial works when the roof was replaced in 2010, Intelect were heavily involved in this project, installing the switchboard into a new switch room, connecting the electrical and mechanical services to various parts of the line.

Special projects

Alongside the contracted electrical work, Intelect are involved with special projects to increase productivity, safety and efficiency of the food processing and packaging lines. The following video, produced by KP Snacks, shows the inside of their manufacturing plant on Teesside. Below the video we've described projects that Intelect have worked on as part of their ongoing relationship with KP.

Process Monitoring

Process monitoring allows the client to measure the input and output of particular production line, helping to optimise energy conservation and performance.

Working with the KP team, Intelect have installed energy monitors, airflow meters and photocells including the design and manufacture of any brackets, fixings and guards.

Conveyors and robotic systems

Most of the conveyor systems used to transport product around the facility were designed, manufactured and installed by our mechanical and electrical teams. The robotic auto palletisation equipment was purchased from a third party company and installed by Intelect as part of the packaging line.

Access bridges and inspection platforms

Our mechanical team were also involved in the design and installation of stepover, access and inspection platforms, all of which are built in-house to BSEN 1090.

Electric, air and water supply

During the process area roof refurbishment in 2010, Intelect installed:

  • Emergency lighting.
  • Electric supplies for lighting and machines.
  • Airlines for pneumatics actuation.

Additional pipework and air handling units were designed and installed by Intelect to provide:

  • Steam & condensate pipework.
  • Air handling units and extract fans.

The team

John Henderson’s team at KP are self managed and responsible for their own equipment and practices on site.

  • All staff are IPAF accredited.
  • Dressed in all the appropriate PPE for the food industry with internal pockets.
  • Single piece food safe pens.

We recently purchased an additional MEWP (Mobile Elevated Work Platforms) and podium scaffolds to reduce the need to use stepladders on site, the podium scaffolds provide a stable and compact platform that allows staff to work comfortably and safely at lower heights. The MEWP's can also fit into tighter spaces and they extend to around 5.5 metres, for heights in excess of this we also keep scissor lifts and boom lifts on site.

Intelect are a multidiscipline company and are able to support the KP team with skills in order for them to achieve their daily activities or project work.

Project Information

Project: Various
Client: KP Snacks
Sector: Food & Beverages
Discipline: Various
Value: Various

Additional Information

Find out more about this project or the services we provided please contact a member of our team:

Teesside: 01642 878784

Humberside: 01472 344901

The Midlands: 01455 286071

NWL Howdon Bio-Methane

NWL Howdon Bio-Methane

Case Study : NWL Howdon Bio-Methane

Following on from the success of the Bran Sands PTA Biogas Reuse Project in 2012 NWL once again chose to engage Interserve Construction Ltd as Main Contractor on the new Bio-Methane ‘Gas to Grid’ Project at Howdon.

The success of this project would be measured upon the ability to deliver the project on time, one budget and to the highest quality, As with Bran Sands, Interserve chose Intelect UK Ltd as their preferred electrical sub-contractor based upon our ability to deliver on these success factors.

Work commenced on the site in late July 2014, with the first tasks being the earthing of the formwork within the foundations of the Grid Entry Unit, Pre-Treatment Plant, Bio-Methane Upgrade Plant, Transformer Plinth and, as shown in the picture below the LV Switch Room plinth. Additionally as a part of a dedicated TNS Supply an Earth Rod Nest was installed adjacent to the LV Switch Room.

As well as heavy power distribution there was a significant amount of gas monitoring instrumentation installed, with a large proportion installed within Hazardous Areas. Intelect UK Ltd provide our Installation electricians with ‘CompEx’ training giving them the flexibility to work within many sectors of the production industry including, chemical and petro-chemical. The picture to the right shows one of these Hazardous Area installations, this one being a pressure transmitter and electric actuator at the Pre-Treatment Plant

The overall scale of the project can be seen from the picture to the left. In the foreground we can see the Pre-Treatment Plant with the gas export line disappearing uphill to the Grid Entry Unit. In the background we can see the Plant Rooms and Bio-Methane Process area with the Absorption, Desorption and Flash columns clad in scaffold. To the left are the Propane Storage Tanks with a steel protection cage fitted over

The project brought together contractors from across Europe, all with a common goal of delivering a ‘Gas to Grid’ deadline of the 30th November. The Interserve site project team led by Graeme Eagling kept the project on track and with excellent collaboration between all stakeholders the target date was achieved. We look forward to continuing our good relationships with both Northumbrian Water & Interserve Construction Ltd.

Project Information

Project: NWL Howdon Bio-Methane
Client: Interserve Construction Ltd
Sector: Utilities, Renewables
Discipline: Electrical Installation
Value: Various

Additional Information

Find out more about this project or the services we provided please contact a member of our team:

Teesside: 01642 878784

Humberside: 01472 344901

The Midlands: 01455 286071