Intelect 20th Birthday

Our 20th anniversary a birthday to remember

This year Intelect celebrates 20 years in business, are named amongst the North Easts Fastest 50 companies in 2017 and are leading the field in our disciplines with a turnover in excess of £20 million per year.

To say that we’re proud of our staff and their achievements is an understatement, so on Saturday 14th October 2017, we came together as a company to celebrate our 20th birthday.

The venue was The HUB at Teesside Universities student union bar, with musical accompaniment by The Last Anthem band, casino tables and a hot and cold buffet.

The evening was hosted by directors, Fran Cormican and John Thompson, who commenced preceedings by thanking everyone for attending, followed by a review of how Intelect began, their growth and expansion, concluding with their hopes and targets for the business going forward.

Tom Blakemore receives the Charlie Baker Apprentice Award

The Charlie Baker Apprentice Award is given in memory of a well loved and successful member of our team, who sadly passed away in 2014. The award, which was voted for by the directors, was presented to Tom Blakemore by Janet Baker (Charlie’s wife), in recognition of the work ethic he has demonstrated throughout his apprenticeship at Intelect. 

A special thanks

In recognition of their support the directors gave out flowers to their wives. Miranda and Lyndsey were thanked for organising the event and last but not least Hazel Hewitson (Accounting Manager) was recognised for “being their rock” throughout the 20 years, since Intelect’s formation.

A great night was had by all

As you can see from the gallery below the night was a huge success and continued on into the early hours!

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.

Industrial fryer refurb for KP

Industrial fryer refurbishment

This project was commissioned by KP Snacks and commenced on the 3rd of November 2014. The 10 meter long industrial fryer was stripped, cleaned and refurbed with new and reconditioned parts and wiring.

The work was carried out at our Riverside Park workshops in Teesside and completed by the 26th of November 2014, taking just 4.5 weeks from start to finish. Intelect then delivered and installed the fryer to KP's manufacturing plant in Rotheram.

Steel mezzanine platform

Platform build for Burts Crisps

Intelect were contracted by Burts Chips in Plymouth, to undertake the design, fabrication and installation of their phase 1 mezzanine floor to be installed in their new packaging area.

Our CAD department carried out all the design work for the platform, all fabrication and welding work was carried out in-house to BSEN 1090. On completion of the fabrication process, the platform was then disassembled and transported to Plymouth where we installed the platform and the necessary electrical installations.

foodex exhibition

Foodex 2016

Intelect exhibited at Foodex this year at the Birmingham NEC, and we enjoyed the experience so much we've already signed up for the 2018 show.


Showing 24volt DC safety related electrical Control circuitry consisting of Emergency Stop, guard circuits for machine access Complete with speed monitoring of Motors for stand still.

Teabag Machine Control Panel

Client: Tetley Tea
Date: 2007/2008
Discipline: Panel Manufacturing
Value: £100,000

During 2007/2008 Intelect UK Ltd Panel department completed the project to overhaul a Teabag manufacturing machine at Tetley Tea, Eaglescliffe.

The project required a full mechanical and electrical overhaul which was project managed by our Panel Department.

On completion of the site installation of the new control panel and machine overhaul the machine was EMC tested and fully commissioned on-site by our Engineering team.

Rospen flavour gantry including vibrator supports to sit astride product feed conveyor

Platforms & Gantries

Client: Various
Date: 2010
Discipline: Mechanical Fabrication

All platforms manufactured, supplied and installed are individually designed to suit each application and position.

Below are examples showing various platfoms manufactured in a wide range of material such as powder coated steel, aluminium and stainless steel.

Various views on new frame

Die holder – KP Foods

Client: KP Foods
Date: December 2012
Discipline: Fabrication and Machining
Value: £4,000

Intelect were contracted by KP Foods to assist with a manual handling problem. Working with line operators and engineers we offered a design that was accepted. The original working procedure involved manually turning over heavy valuable die sets. The new frame and die turner was made to minimise manual handling.

This project was completed on time and budget to the highest standard and to the satisfaction of KP Foods.

KP Foods were highly satisfied with the new design improvement helping them to transport the frames more safely to the cleaning area and reduce the level of manual handling required by employees, this was a direct improvement that went over and above of their design brief.

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.