Process Plant Engineering Projects
Project 1
Installation of a Buhler A Mill at Heygates and Sons Ltd, Bugbrooke, Northamptonshire
Having worked for the Heygate family for over thirty years building up a trusted relationship, Brookshaw Stuart was appointed to install the new Buhler A mill. We provided engineers with the expertise to install and fabricate and work alongside the client. Buhler ensured that the installation ran smoothly and was completed on time, to the client’s requirements.
The brief from the client was to fully strip out the old mill and install a completely new staircase tower and entablature for the machinery to be fitted on to. All equipment was then installed and connected with compressed air, blow lines and exhaust ducting.
Challenges on site
Brookshaw Stuart Ltd had a minimum of 15 engineers per day on site ensuring that all deadlines were met and the plant was commissioned to a high standard. The plant is now running to its full potential, producing great flour.
Whilst completing the installation, we also provided maintenance and breakdown cover for the Northamptonshire mill and the other mills and animal feed plants at Downham Market, Norfolk, Icklingham, Suffolk, Tring, Hertfordshire and Bugbrooke, Northampton.
Project 2
Henry Simon Installation Project at Kemira Chemicals, Bradford
Project Brief
The Brookshaw Stuart Ltd installation team were commissioned to undertake this assignment by Satake / Henry Simon at Kemira Chemicals Ltd in Bradford, Yorkshire. We were required to update a 35 year old Satake SRMA 1250 roller mill and replaced it with a Henry Simon HSRM 1250 roller mill.
Challenges on site
In order to access the roller mill to be replaced, Brookshaw Stuart had to temporarily remove the first mill, to gain access, with very little space for removal. Also there were few viable options but to lift the 5000kg machines down from the 3-meter-high gantry.
A 7-tonne forklift was manoeuvred into tight positions and using an aluminium gantry, they were lowered down.
Once the old mill was safely removed, the new Henry Simon mill, hopper and aspiration were installed. This equipment was then handed over to the electricians and the Henry Simon team for electrical connections and commissioning. Whilst the new mill was being connected and commissioned, Brookshaw Stuart reinstated the first mill so it could continue with its operational activities.
The client had requested that the removal and installation of the mills be done on a three day turn round, allowing the electrical work and commissioning to be started on day 4 and the equipment running on day 5.
Successes on site
Due to thorough preparation and assessment of all requirements, the installation was completed in 2 and a half days. It was then handed over to the Henry Simon commissioning team. Kemira Chemicals’ Garry Bazeley was extremely happy with the work ethic of the Brookshaw Stuart engineers, in respect of getting the job done, on time and also, critically, the evident commitment to safety being at the core of the operation.
www.kemira.com
Satake were so impressed with our performance that we have been commissioned to replace the next unit, due shortly.
Project Partners
For more details of our partners in this project please see:
Henry Simon Milling
Kemira
Project 3
Installation of new Satake Mill at Tilda Rice. Rainham, Essex
Long History with Satake, in Rochdale, Manchester & Essex
Brookshaw Stuart and Satake have an ongoing partnership and a very strong relationship nurtured over time. This dates back to when the business was Robinsons Milling Systems, and Thomas Robinsons of Rochdale before that.
We are preferred contractors and work collaboratively with key designers and the sales team. Based largely on the working relationship and the trust built up over time, we were contracted to undertake the new installation package at Tilda Rice, Rainham, Essex.
From an early stage Brookshaw Stuart helped with the removal of old food processing equipment so that the new mill could be installed. Working on site with many other contractors, we successfully installed all equipment required in a safe manner and within the allotted time frame.
Ongoing Maintenance of Food Processing Plant
We have been back on site on several occasions since project completion, to provide maintenance services.
Project 4
Mustard Seed Processing
Installation of Henry Simons Mill Condimentum, Colemans Mustard, Norwich
Having completed the previous mills for Satake, Brookshaw Stuart was invited to tender for the installation of the new Henry Simons Mill for Condimentum. This is the mustard processor for the well known Unilever brand, Colmans.
Successful Co-ordination with other Contractors
The requirement was for us to work alongside the client, TH Whites Projects Ltd and Smiths of Honningham Ltd. The brief was to deliver a high spec food processing plant package. We achieved this through regular on site design meetings and morning briefings. Brookshaw Stuart completed the installation safely and in time.
We take pride in the knowledge that we were part of a specialist team, who safely and in budget, completed the newest of only four such mustard plants in existence.
Process Plant Installation Hurdles
Through the innovative use of a Merlo three-hundred-and-sixty-degree telehandler Brookshaw Stuart managed to install sectional bins through the pre-installed floors in a safe and speedy manner. This required close co-ordination by our team of fully qualified slingers, banks man and Merlo drivers.
Due to the layout of machinery and pipe work, Brookshaw Stuart also had to design and fabricate on site the supports for machines and pipework.
The installation package included compressed air, drag link conveyors, screw conveyors, sifters, bucket elevators, colour sorter hoppers, roller mills, purifiers and bulk bagging systems.
We connected all blow line ducting and compressed air systems, working closely with the electrical contractor and Satake Europe, the milling equipment supplier.
Satake Website Project Description
For a more detailed summary of this project please see the Satake website via this link.
Project 5
Installation of new odour removal equipment in line with the Environmental Agency requirements, at Gilbertson and Page Ltd, Welwyn Garden City.
Working alongside GDE Associates, Brookshaw Stuart was contracted to install a new odour control plant. The new plant drags air from the extruders and dryers, through two new desotec carbon filters. The air is then expelled to atmosphere through a t30 metre high chimney.
Challenges On Site – Minimal Time Frame
The client’s requirements were that all processes that were in place for the removal of the odour from site had to remain active whilst installation was completed.
Due to the Environmental notices that would have been placed on Gilbertson and Page for not meeting strict odour control, the planning and installation had to be completed in a minimal time frame.
On Site Structural Steel Fabrication & Chimney Relocation
To speed up the installation process Brookshaw Stuart fabricated on site all structural steel and access platforms and then installed them. 1200mm stainless steel duct was fitted and, where required, stainless flanges welded to ensure accuracy of compliance to design.
Once all the ducting and filters were in place, shut downs had to be planned so that productivity of the mill was not impacted.
This required meticulous planning by Brookshaw Stuart, to remove a thirty metre high chimney stack from the middle of factory. It was then transported to a new location at the rear of the building and reconnected.
Project 6
Removal and reinstallation of tea mixing plant from China to Poland
Through previous projects for Nestle Purina and for the the project manager Peter Davenport, Brookshaw Stuart was commissioned to organise the removal of a tea blending plant, electrically and mechanically, from China to Poland and reinstate to the same output and quality.
Challenges on site
The project required communication between three different countries China, Poland and the UK. Working with engineers, consultants and fabricators, Brookshaw Stuart engaged GDE Associates to devise a working layout for the space in Poland. We also engaged Sterling Fabrications, Salford, to fabricate a bespoke platform that would encase the Boon mixers without hindering the load cell weighing system.
Due to stringent controls in China, equipment that was sent for the removal of the tea blending plant was impounded. So with minimal notice, we had to source locally, the equipment for the plant removal. Once the equipment was removed it was packed up and sent via rail to Poznan in Poland. Here it was then unwrapped and manoeuvred into position through an active factory and re installed.
At every stage of this operation we factored in the critical safety considerations of our engineers and the employees of ABF Twinings.
Project 7
Animal Feed Upgrade for SugaRich Animal Feed, Harlow, Essex
The project required the removal of an old vertical and horizontal screw used to process animal feed and to install new Wrights Dowsin equipment. Also to install a new 7 metre vertical screw auger and a 15 metre screw auger, supported by two new concrete panels.
Brookshaw Stuart engineers disconnected the equipment electrically and mechanically and utilising telehandlers and MEWPS, removed and installed concrete panels and other equipment.
Work Completed Ahead of Schedule
As the removal and installation program was completed ahead of plan, we were asked to repair old equipment whilst on site. This involved fabricating new brackets for concrete panel installation and repair of screw conveyors.
Challenges we met
The removal and installation of the new equipment was challenging due to the height of the equipment within proximity of the roof. The roof sloped and gave head height of approximately 1 foot. It required the engineers to top and tail the equipment using the telehandlers and chainblock.
Client Testimonial
I have worked with Brookshaw Stuart on numerous projects and they never fail to achieve expectations. They overcome any hurdles with a ‘can do’ attitude. Thanks for a great job done within the specified shutdown. Above and beyond!
Graeme Cooke – SugaRich
Project 8
Heygate Ltd (Tring) Removal of Robinsons Sifters and Installation of New, Tring, Hertfordshire
Due to the age and ongoing maintenance issues with the Sifters at Heygate Tring the decision was made to install 3 new sifters, Brookshaw Stuart was contracted to complete 3 staged night shut downs to remove and Install new equipment.
The project involved the dismantling and removal and building and installation of new with as least disruption to production as possible this was completed over 3 night shut downs with 2 teams of engineers.
Challenges
The major challenge with the installation of the new sifters was the removal from the floors and taking of the new sifters onto the floors, equipment had to be removed to gain access for the installation.
Client Testimonial
Brookshaw Stuart Ltd did what they said they were going to do completed the 3 shut downs on time with as little disruption to production as possible, well planned shut downs thanks once again
General Manager
Project 9
Heygate Ltd, Tring, Hertfordshire
Ongoing works at Heygates Tring, Brookshaw Stuart provide long term labour to deal with projects, general maintenance and reactive maintenance below are some of the items that we have fabricated during 2022 – 2023
The engineers on site measure and fabricate the clients requirements to update the plant, this could be new platforms, access stairs, cat ladders, ducting, hopper, pipe work, brackets for supports, gantries etc.
Challenges
Installation of fabricated items due to logistics of the equipment and plant movement.
Client Testimonial
Brookshaw Stuart Ltd have always been a cornerstone within the Heygates Mills providing excellent engineering support on the upkeep of the mill with ongoing projects, regular maintenance or reactive maintenance and 24 hour call out.
General Manager
Project 10
Heygate Ltd Ongoing Project Installation of Buhler Integrated High Compression Grinding Mill, Bugbrooke, Northampton
Brookshaw Stuart were tasked with the installation of a New Buhler Mill that was used to process fine flour back in March 2021, the installation was completed without any supervision and was done all in house.
Challenges
The area that the client wanted to put the new Buhler mill into could not contain the whole system in that area, so engineers had to split the system up and move the filter to another area and then re pipe. The system has now been running for nearly two years without any problems.
Project 11
Heygate Ltd Ongoing Project Silo Storage, Bugbrooke, Northampton
The pandemic helped the flour industry increase production as it has seen more and more home bakers at home with this influx production of flour has gone through the roof. The client needed to increase flour storage and purchased some bins. The Brookshaw Stuart team then set about modifying and making new sections on site to make them fit for purpose.
Once the silos had been installed the engineers on site fabricated all structural steel, access platforms plus stairs they also came up with a bespoke access system for the drivers to safely access the tops of the tankers. The images below show the development of the bins from start to finish inclusive of all pipe work and ancillary equipment to move the flour from A to B.
The penthouse enclosures at the top of the silos came in pre made engineers just had to assemble and weld in a warehouse which was no easy task. Once the silos were placed in position the crane company then had to lift on the penthouse enclosures and pipe work to the silos began
Challenges
The overall project was quite challenging from fabricating in a warehouse to designing and fabricating platforms and stairways without any fabrication drawings and logistically making it and sending it to be galvanised then installing.
