The client

NORTHERN FOODS – A high volume conveyance food manufacturer supplying major supermarkets with chilled and frozen produce.

The brief
Following a major relocation plan Systems Design were approached by Northern Foods to help integrate production lines into a new factory unit. It was important that Northern Foods retained some production at their old factory unit to help bridge the relocation gap in order to try and minimise production interruption. Initial thoughts was to construct a single additional production line using spare items of plant which they used to cover breakdowns. Following joint discussions we identified that although this was a workable plan the  makeshift production line would only work at about 67%, as it was not an integrated system. Therefore a solution would need to be found to mitigate this if possible as well as designing an integrated system for the new factory.

Systems Design proposals
Our first proposal was to develop the new factory layout with the intention of installing five production lines into the space that presently housed only four production lines. Northern Foods liked this idea as it firmly demonstrated increased productivity at the new site. 

Our second proposal was to plan the power distribution for the entire new factory. This  consisted of a plant room that would house a form 4 MCC to distribute power to all services (lighting, chilling etc.) and to each individual item of plant in the production area (conveyors, enrobers etc.). We advised that a matrix of cable tray be designed with individual drops to the position of each item of new plant. Each drop should have an isolation device and socket to deliver power.

Our third proposal was to redesign the conveyor system which was to be built from the spares as suggested. If successful, this would allow production to continue at 100% efficiency and solve the reduction in production problem. We also proposed the design of a new integrated PLC control and instrumentation panel to control the newly modified production line.

After much discussion the Systems Design proposals were accepted and a decision made to move forward with the project. The time frame for the project was set at 16 weeks.

Design & Production
The new production layout was drawn and approved within a week during which time the design for the MCC was completed by modifying an existing design to suit the new application and loadings. An order was placed with a local panel builder to ensure production time was available to meet timelines.

The design of the additional items for the conveyor system was undertaken to ensure that this would operate at 100% efficiency as requested within the brief. The redesigned conveyor was then contracted out for manufacture. 

A design was completed for the matrix of cable tray and in order to meet timelines we instigated installation as the electrical design was undertaken.

Within ten weeks the first production line was in and producing product for orders.

Phase two
With the newly modified production line producing product efficiently, an existing line from the old factory was now taken off line and removed. This was then fully serviced for installation in the new factory with no loss of production. The time taken to achieve this first move with installation and commissioning was one week as predicted, resulting in the project being completed within the time allotted.

In the end the project was completed in 15 weeks, one week earlier than the projected timeline.

The bonus on this project for the client was that for a minimal capital outlay on new plant (with the exception of the conveyors and PLC system) they gained a 20% increase in production capacity immediately and still had the space in the new factory to achieve their original goals 

These results were achieved with good preparation and experienced planning .

Systems Design provides electrical engineering expertise, design and management services in the following key areas:

. Full Electrical Design 
. LV Panel Design
. MV Control System Design
. C & I Scheme Design
. Motor Control Centre Panel design
. Control Systems Design
. Electro Mechanical Control Systems Design
. Electro Pneumatic Control Systems Design
. LV Power Distribution Systems Panel Design
. Project Management
. PLC/HMI Hardware Design
. CAD Drafting Service
. MCC Motor Control Centres
. Power Distribution Panels
. SCADA Systems Hardware Design
. AC and DC Drives