WHAT WAS THE ISSUE?
Our client, a manufacturer and supplier of ruminant compound feeds and blends based near Carlisle, had added new silos and weighers to increase the size of their mill and production capacity around six years ago. However, they were still using one of the original weighers and dischargers which had been in use since long before that. This existing weigher and discharger needed to be replaced due to the wear and tear from many years of use. Without this upgrade there would be an increased risk of future breakdowns which could result in loss of production time.
The client wanted us to survey the existing weigher and discharger, ahead of supplying updated replacement equipment.
WHAT WAS OUR SOLUTION?
We initially attended site to discuss the customers’ requirements and carried out the survey.
We then designed a bespoke solution to meet the client’s needs, before the manufacturing was carried out at our workshop in York, and we sourced some components from our approved suppliers.
Our team then headed to the site a few days before the installation to complete preparation and preinstall visits, ensuring that the end result for the project was a success.
While the functionality of the clients’ machines remains unchanged, we enhanced durability by galvanising the replacement equipment for longevity. Unlike the original painted machines that showed significant signs of corrosion, our galvanised machines are designed to withstand the test of time and harsh environments to ensure the client gets the best value for their money.
The installation process for this project was slightly more challenging than others due to the location being between the existing silos on the site. This meant there was a lot of manual work, with the aid of manual chain blocks and involving correct rigging and slinging techniques which all our engineers are trained in, including regular refresher training, and have extensive experience of using.
HOW WE DID THE INSTALLATION
Both machines are situated deep within the factory complex, approximately 46 metres from the nearest open area. As these are also situated outside, standing 26 metres tall in height, the only way to suitably support & disassemble was by use of a crane.
As we have provided similar projects to this one for our client before, we again used their preferred local crane company in the area, Forsyth of Denny, who were a vital part of the installation team.
Both machines created by ISF were part assembled in the customer’s yard & craned into position using a large Liebherr LTM1150 crane, capable of lifting 3.5t at the required working radius of 46m.
We had originally planned to install both machines on our first visit, however, a severe change in wind conditions halted lifting operations as wind speeds exceeded gusts of 40 mph. Luckily the first machine was changed just in time, otherwise the plant would have been non-operational until weather conditions changed.
We adapted to the unpredictable weather conditions, and although we were unable to install the larger 17m high machine on this visit, we rescheduled a second visit for 3 days when the plant was next available for shut-down works.
As crane lifting operations were completed by Forsyth of Denny under ‘contract lift’ they were able to supply their own lifting team for managing crane operations under all required health and safety regulations including LOLER (Lifting Operations and Lifting Equipment Regulations) & CPCS (Construction Plant Competence Scheme).
Our team required MEWP licences to gain safe high-level access using a cherry picker or manually elevated work platform.
WHAT WAS THE OUTCOME?
Due to our efficiency, our team completed the installation of the new weigher and discharger within the planned 3-day shutdown period. This gave the customer peace of mind that that the mill could continue to operate efficiently without unplanned disruption and no loss of production time.
Our client was pleased with the work completing, saying:
‘Overall, very satisfied with how the project went hitting the agreed installation timeslot.
Plenty of bodies on site to do the physical graft is always key, along with the preinstall visits to ensure all bases are covered’.
