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.

Bagging machine

De-Bagging Station

Intelect were contracted by Spicers, North Shields, to undertake the design, fabrication and installation of a frame that has the ability to take different sized tea blend bags FIBC & IBC solid containers direct into the blending system.

Mezzanine storage platform-britvic

Mezzanine storage platforms at Britvic

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.

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.

Northumbrian Water Framework Agreement

NWL Framework Announcement

Northumbrian Water  Framework Agreement

Kevin Willis - Contracts Manager at Intelect was pleased to announce that, "Intelect are a preferred supplier for the forthcoming Northumbrian Water Framework Agreement."

The scope of works Intelect will be involved with include, electrical installations and mechanical fabrication. Intelect have worked extensively with NWL on previous projects (see below) and we feel the effort put into obtaining BSEN 1090, (which covers the manufacture of handrails, access gantries and platforms) has helped us secure future work for our mechanical fabrication team.

Congratulations to all those involved in the tender process and good luck for the future.

Intelect & NWL projects

Intelect have extensive experience in the utility sector and have worked on a number of projects for Northumbrian Water including:
  • NWL Howdon Bio-Methane

    NWL Howdon Bio-Methane

    Client: Interserve Construction LtdDate: November 2014Discipline: Electrical Installation Following on from the success of the Bran Sands PTA Biogas Reuse Project in 2012 NWL once …
  • Electricity at Work Regulations (EaWR) Waste Water Delivery

    Electricity at Work Regulations (EaWR) Waste Water Delivery

    Client: JN BentleyDate: September 2014 - OngoingDiscipline: Electrical Installation On behalf of Northumbrian Water Limited, JN Bentley Ltd contracted Intelect UK Ltd, under New Engineering …
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. 

Galvanised and installed steel work at Stewarts Park Valve Chamber

High level platform

Description: Stewarts Park Valve Chambers
Client: JN Bentley
Date: March 2011
Discipline: Mechanical Fabrication
Value: £20,000

Intelect were contracted by JN Bentley to design, fabricate and install high-level platform around a compact 1m diameter valves due to NWL operatives having to climb over valves in the chamber which was causing health and safety issues.

The platforms were constructed in mild steel channel and angle in our workshop, from here they were taken to site fitted in black form and removed to be galvanised and then refitted on the underground chambers.

We were given 3 months to construct 3 platforms which was completed to the desired timeframe. The client was pleased with the quality and rapid turn around and consequently further similar and further projects to reduce health and safety hazards have been awarded.

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.