Towards the end of 2024 we completed a series of projects at an animal feed mill in North Yorkshire, which specialises in the production of high quality micronised cereals and pulses for the animal feed and brewing industries.
The final phase of these works was the optimisation of the conveyor in the raw material intake system.
What was the issue?
The clients existing system on the silo intake route included a wetting conveyor to add moisture to the raw materials, such as wheat, sugar beet, maize, barley and peas. The wetting conveyor then fed the silo top conveyor, which deposited the materials into 5 silos where it is stored until called for manufacturing.
This process had become outdated due to changes in their systems and production methods over the years which meant the client no longer needed the wetting process. Both the wetting conveyor and the silo top conveyor were purely being used for the transfer of the raw materials, meaning they were unnecessarily running two conveyors to transfer product into the silos. As the conveyors were aged and ready for replacement, this also presented the opportunity for upgrades on the process to be completed.
What was our solution?
With no need to replace both conveyors, we instead recommended replacing with a single conveyor extended by 3 metres (to compensate for the length of the redundant wetting conveyor).
After confirming with the customer and completing surveys on site, we designed the replacement conveyor which was also upgraded to meet ATEX requirements including geared motor unit, blockage sensors, and speed monitoring, meaning an improved level of health and safety. We included an integrated magnet chute to remove tramp material, reducing contamination risk meaning better quality of product. The replacement system also included 5 new pneumatically operated slide valves to allow the correct materials to be transferred into the relevant silo. We also reconfigured the arrangement of the conveyor and valves to improve access to the system. The conveyor and slide valves were then manufactured at our facility by our highly skilled and experienced engineers, and following final quality checks, delivered to our client ready for installation.
How we carried out the installation
Our project managers liaised with the customer to agree an installation date so that the customer could adequately manage their production schedule. Our qualified in house Appointed Person for Crane Operations completed all necessary health and safety plans and documents, including lift plan, method statements and risk assessments, meaning that the entire project was managed and controlled by ISF from start to finish.
Following hiring a crane from Elmsley Crane Hire, we removed the redundant conveyors and installed the replacement over an agreed 3-day period. As the replacement conveyor is 25 metres long in total, it was assembled on site ahead of installation and lifted into place in 2 x 12m sections before being connected by our installation engineers.
What was the outcome?
Following electrical commissioning the new and improved conveyor was up and running and is now giving the client peace of mind that it is more reliable, more cost effective, and more efficient. By replacing with one conveyor, our customer will save on maintenance and energy costs, as they will now be running 1 motor instead of 2.
We are already working on some new projects for this client, so watch this space for more updates and exciting upgrades taking place this year. Check out some images of this project below!
What was the outcome?
Following electrical commissioning the new and improved conveyor was up and running and is now giving the client peace of mind that it is more reliable, more cost effective, and more efficient. By replacing with one conveyor, our customer will save on maintenance and energy costs, as they will now be running 1 motor instead of 2.
We are already working on some new projects for this client, so watch this space for more updates and exciting upgrades taking place this year.
