KP Billingham and Intelect

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.

Mobile Elevated Work Platform MEWP

Mobile Elevated Work Platforms (MEWP) a proactive approach to Health & Safety

Mobile Elevated Work Platform MEWP

Intelect receive praise from KP on their proactive approach to working at heights at their Teesside site

"This is just the type of proactive approach we want to mitigate the risk of WAH." HSE Manager at KP Snacks, Teesside, describes Intelect's decision to invest in additional equipment for their staff. Intelect currently have 5 regular members of staff working on a long-term contract at the snack manufacturers Billingham site. The team headed up by John Henderson are responsible for the electrical installations and maintenance of the building. Intelect also work alongside KP's own staff to design, manufacture and install equipment that monitors and improves the performance of production line. 

podium scaffolds for working at height

As part of their daily activity, the team are working at heights as described by the Health and Safety Executive

"Work in any place where, if precautions were not taken, a person could fall a distance liable to cause personal injury. You are working at height if you:

  • work above ground/floor level
  • could fall from an edge, through an opening or fragile surface or
  • could fall from ground level into an opening in a floor or a hole in the ground

Work at height does not include a slip or a trip on the level, as a fall from height has to involve a fall from one level to a lower level, nor does it include walking up and down a permanent staircase in a building."

Investing in safety

Whilst step ladders are suitable for low-risk and short duration tasks (under 30mins) Intelect were keen to impress upon KP their commitment to going above and beyond what is required by legislation if it will make the working environment safer.

The additional MEWP's (Mobile Elevated Work Platforms) and podium scaffolds were purchased 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. All staff working at heights are IPAF (International Powered Access Federation) certified.

Bio-Methane ‘Gas to Grid’ Project

NWL Howdon Bio-Methane

Client: Interserve Construction Ltd
Date: November 2014
Discipline: Electrical Installation

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.


Completed installation at Potto Sewage Pumping Station, North Yorkshire

Electricity at Work Regulations (EaWR) Waste Water Delivery

Client: JN Bentley
Date: September 2014 - Ongoing
Discipline: Electrical Installation

On behalf of Northumbrian Water Limited, JN Bentley Ltd contracted Intelect UK Ltd, under New Engineering Contract (NEC3) Option A, to complete the Electrical Installation work associated with the EaWR Waste Water Delivery Scheme. 

The objective of the scheme was to bring all electrical equipment up to existing standards, including; 17th Edition BS7671, Electricity at Work Regulations 1989, and NWL E0103, E0104, E0702 specifications.  

The scheme is to be undertaken over an 18-month programme, consisting of 23 sites. Although the objectives of all sites were the same, the volume of works required was specific to the respective site, some sites requiring a full electrical refurbishment, whereas, some sites only required part refurbishment, dependant on equipment currently installed.   

As of December 2014, working collaboratively with NWL, JN Bentley Ltd and other 3rd party installers, we have successfully completed 5 of the 23 sites to the gratification of all parties, within programme and with no Health and Safety issues to report.

The picture to the left shows the completed installation at Potto Sewage Pumping Station, North Yorkshire. This particular site required a full site electrical refurbishment including: removal of redundant and non-complaint equipment; installation of a new MCC Panel (Supplied by a 3rd party), earth protection and installation of Building Services. The site was also tested to ensure it compiled with the required standards and specifications.

The picture to the right shows the inside of the Telemetry Outstation. During the installation, the existing telemetry outstation was retained, and alarm signals were changed sequentially from the old equipment to the new to enable the site to be kept operational at all times. This element of works is critical to the success of any refurbishment works carried out to operational sites as disruption to water supplies or sewage discharge can lead to financial penalties to Northumbrian Water Ltd.

Through Northumbrian Water Ltd, JN Bentley have awarded Intelect UK Ltd major framework projects for the past 8 years and continues to do so.  We have worked collaboratively on various projects ranging from small pumping stations refurbishments through to new water treatment processes.

Pallet straightening rig developed for one of our major clients, to feed their automated Palletisation unit.

Various Projects

Client: Various
Date: Various
Discipline: Design, Fabrication, Machining, Electrical, Control Panel
Value: Various

Above are samples of various projects undertaken to show the wide range of disciplines, principally showing the fabrication disciplines.

These examples show a small but varied view on our capabilities. We offer a wide range of expertises and knowledge, working closely with a vast and varied range of clients to provide bespoke engineering solutions.

pictures show the PLC cubicle after the upgrade.

Tata Steel – Ijmuiden – Cyclo – Convertor Drives Upgrade

Description: Tata Steel – Ijmuiden – Cyclo – Convertor Drives Upgrade
Client: GE Energy
Date: 2012/2013
Discipline: Panel Manufacturing, Electrical Installation, Mechanical Fabrication, Machine Services

Intelect UK Ltd’s Panel manufacturing department were awarded the contract by GE Energy to upgrade obsolete drive equipment at Tata Steel Ijmuiden, Netherlands. 

Intelect’s scope was to supply, manufacture and install new hardware based on GE Energy’s design.

Above pictures show the PLC cubicle before and after the upgrade. Main scope of work was to replace the obsolete Siemens S5 controller with GE Energy’s new control scheme which required manufacturing new control backplate assemblies off-site the minimise site installation time.

The project was carried out in 2 phases to extremely tight deadlines to coincide with production requirements, Intelect UK Ltd completed the hardware installation within a 48hour window requiring a team of 18 Electricians working round the clock. The project was brought in on budget to a high degree of quality. 

Six knife gate valves prior to having its electric actuator fitted

Browns Point Valve Actuation

Description: Browns Point Valve Actuation
Client: JN Bentley
Date: March 2014
Discipline: Electrical Installation

NWL’s Browns Point SPS is a 3 pump dry well sewage pumping station located in Cullercoats, Tynemouth. The station was prone to blockages meaning that NWL operators were required to mechanically isolate the pumps to de-rag. The existing manually operated knife gate valves were fitted with Rotork electric actuators by a 3rd party with the electrical works undertaken by Intelect UK Ltd, these improvements greatly increased efficiencies when de-ragging and thus reduces the time spent carrying out the works.

The picture to the left shows one of the six knife gate valves prior to having its electric actuator fitted. The works were initially sequenced such that the mechanical contractor would complete his activities prior to the start of the electrical works.

In the event the sequence of works changed, the mechanical contractor encountered difficulties in removing the flange bolts. This delay caused an impact on the overall programme as JN Bentley had site establishments and site management in place for a finite duration.

As a result we came in early and installed the containment, cabling and local isolators prior to the mechanical works, once the mechanical contractor finally completed his works we returned to site to complete the cabling between the local isolators and the electrical isolators.

The picture to the right shows one of the modified valves incorporating the electric actuator, local isolator and containment along with power cabling, labels and earth bonding.

During the NICEIC testing it became apparent that there were departures from BS7671, Specifically it was not physically possible to identify the protective bonding conductors to the water services pipework and structural steelwork. As a result we were unable to issue an electrical installation certificate, in lieu we issued a schedule of electrical test results along with a report outlining necessary improvements to be undertaken by the owner.

To conclude although the installation did not go entirely to plan the works were still completed within the required timeframe, no health and safety issues arose and resources were efficiently redeployed and returned to bring the project in on budget.

JN Bentley has been one of our NWL clients over the last 8 years and continues to award Intelect UK Ltd major framework projects. We have worked on various projects ranging from small pumping stations refurbishments through to new water treatment processes.

Tetley Tea guarding and control panel

PUWER Upgrades at Tetley Tea

Client: Tetley Tea
Date: June 2010
Discipline: Fabrication, Electrical and Control Panel
Value: £40,000

Intelect were contracted by Tetley Tea to undertake PUWER upgrades on an existing machine. We undertook the design, installation, fabrication and commissioning of the Guarding and Control System.

This was our first calibration on a PUWER Guarding project. The client was pleased with the quality and rapid turn around consequently further similar projects have been awarded and commissioned.

We have also completed various levels of guarding systems with differing requirements from each client. We have also trained key personnel in the latest PUWER regulations enabling us to offer bespoke solutions.

KMG Systems Limited

KMG is the global leader in the design and manufacture of conveying and seasoning systems for the food industry. We have over 40 years of experience and the best engineers in the industry.

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Chelsea Underground Pitch Heating System

Chelsea Underground Pitch Heating System

Client: Inditherm (Chelsea FC)
Date: 2005
Discipline: Electrical Installation and Panel Manufacturing
Value: £50,000

Intelect UK Ltd were contracted by Inditherm to undertake the installation of the underground football pitch heating system at Chelsea's training ground. This was Intelect UK Ltd’s first project with a football club. The completed control panels were installed on-site by Intelect’s installation team on schedule.