Archives for Case Study

Flour Silos Installation

General Mills known as GM is an American Fortune 500 corporation, primarily involved with food products. The company markets many well known brands such as Betty Crocker, Yoplait, Colombo, Totino’s, Jeno’s, Pillsbury, Green Giant, Old El Paso, Häagen-Dazs, Cheerios, Trix, and Lucky Charms. Its brand portfolio includes more than 100 leading global brands and numerous category leaders around the world.

FEG were commissioned by GM in the UK to Project Manage a £650K cost saving project under CDM to install larger capacity flour silos and batch weighing facility for the mixers. This included building a new structure to house the sieving and plant room.

FEG managed the multi function project team, provided site management, liaised with business neighbours and the local authority to ensure the project was completed on time and budget.

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Flour Weigh Head Installation

General Mills known as GM is an American Fortune 500 corporation, primarily involved with food products. The company markets many well known brands such as Betty Crocker, Yoplait, Colombo, Totino’s, Jeno’s, Pillsbury, Green Giant, Old El Paso, Häagen-Dazs, Cheerios, Trix, and Lucky Charms. Its brand portfolio includes more than 100 leading global brands and numerous category leaders around the world.

FEG was commissioned by GM in the UK to Project Manage the automation of flour weighing into a mixer.

The space constraints made installation difficult and involved building modifications and careful design of access platform.

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Food Ingredients and Production Facilities

United Biscuits known as UB, is a British multinational food manufacturer, makers of McVitie’s biscuits, Jacob’s Cream Crackers, and Twiglets. McVitie’s is a British snack food brand owned by United Biscuits.

FEG has worked with United Biscuits for a decade and has been commissioned to carry out numerous projects throughout the groups McVitie’s food production plants.

  • Batter Depositor
  • Chocolate Biscuit Cooling Conveyor
  • Chocolate Tank Removal
  • Cake Ingredients Mixing
  • New Handwash Station
  • New Sugar Screw Feed System
  • Silos for Bulk Feed
  • Snack Coating
  • Tank for Plain Chocolate Feed Upgrade
  • Upgrade Plain Choc Feed System

FEG provides Project Management from feasibility to hand-over, managing multi-discipline project teams and ensuring United Biscuits internal procedures were fully met. FEG were able to apply a range of technical expertise and experience to validate the designs and equipment put forward by various suppliers.

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Gas Turbine Ventilation System

Scottish & Southern Energy (SSE) is a leading electricity and gas company, operating mainly in the UK and Ireland. Keadby Power Station is a 720 MWe gas fired power station near Scunthorpe in North Lincolnshire.

Scottish & Southern Energy commissioned FEG to improve their ventilation systems for 2 power producing gas turbines at Keadby Power Station.

This included designing duct work systems to disperse any gas from the cylinders, provide cooling air, install new fans with improved access and performance.

Both access and space constraints were very difficult and required in-depth design to overcome, including 3D modelling the turbines.

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Heat Recovery System for Workshop Heating

Kimberly Clark is a global personal care corporation that produces mostly paper based consumer products. Kimberly Clark brand name products include Kleenex facial tissue, Kotex feminine hygiene products, Cottonelle, Scott and Andrex toilet paper, Wypall utility wipes, KimWipes scientific cleaning wipes, and Huggies disposable diapers.

Under a full turn-key project Kimberly Clark commissioned FEG to Design, Supply, Install, Site Supervise, and Commission a system to utilise waste heat from four 160kW compressors to heat various workshops and other work areas of the plant.

The system had to ensure sufficient compressor ventilation to avoid overheating, minimise the effect of drafts and noise in the work areas. The complete installation had to be completed without affecting the compressor uptime as this directly impacted on production. The project costs were completely recouped with a payback of less than 2 years.

This project involved site management, control of contractors, budget management and programme control.

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Heat Recovery System

Kimberly Clark is a global personal care corporation that produces mostly paper based consumer products. Kimberly Clark brand name products include Kleenex facial tissue, Kotex feminine hygiene products, Cottonelle, Scott and Andrex toilet paper, Wypall utility wipes, KimWipes scientific cleaning wipes, and Huggies disposable diapers.

Kimberly Clark engaged FEG to Design, Supply, Install, Site Supervision, and Commissioning a turnkey project to recover waste heat from compressors and heat various areas of the factory.

The system had to ensure sufficient compressor ventilation to avoid overheating, minimise the effect of drafts and noise in the work areas. The complete installation had to be completed without affecting the compressor uptime as this directly impacted on production.

This project involved site management, control of contractors, budget management and programme control.

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High Capacity Pastry Production Line

General Mills known as GM is an American Fortune 500 corporation, primarily involved with food products. The company markets many well known brands such as Betty Crocker, Yoplait, Colombo, Totino’s, Jeno’s, Pillsbury, Green Giant, Old El Paso, Häagen-Dazs, Cheerios, Trix, and Lucky Charms. Its brand portfolio includes more than 100 leading global brands and numerous category leaders around the world.

FEG was commissioned by General Mills in the UK to undertake from feasibility to hand-over a £3.8m project to install a new high capacity frozen pastry production line.

This was a cost saving project to replace 3 production lines with one, largely automated line and included Central Palletising.

FEG headed a multi department project team and various sub-teams, provided site supervisor and CDM coordinator, giving the client a Total Project Management Package.

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New Organic Production Facility – Ingredients Feed

United Biscuits known as UB, is a British multinational food manufacturer, makers of McVitie’s biscuits, Jacob’s Cream Crackers, and Twiglets. McVitie’s is a British snack food brand owned by United Biscuits.

United Biscuits commissioned FEG to Project Manage, under CDM, the ingredients feed and mixing requirements for a new facility. The project value was approximately £1m.

The project for the new organic production facility ingredients feed at the McVities plant involved heading a multi department project team, controlling project spend, assigning resources, controlling and writing the Construction Phase Health & Safety Plan, supplier approval, control of contractors, issuing permits.

FEG had overall responsibility for ensuring all building modifications, plant modifications and new equipment met specification, achieved production targets, were within budget and timescale.

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Oil Dosing System

Calder Foods are the market leader in the manufacture of innovative on trend products for the UK sandwich industry. These include: sandwich filings, marinades & cooked meats, salads, sauces and chutneys.

As such the company is committed to providing its customers with total confidence in its products by the implementation of a formal, comprehensive and established HACCP & Quality Management System.

The Problem: Calder Foods required an Oil Dosing System for their food manufacturing factory.

The Solution: FEG project managed the complete project which included:

  • Develop User Requirement Specifications
  • Design Process and Produce P&ID
  • Obtain Various Quotations
  • Procure Equipment
  • Manage Installation and Commissioning
  • Conduct Employee Training
  • CE Mark the System
  • Develop O&M Manual and Planned Maintenance Schedule
  • Hand Over all Relevant Documentation

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Power Generation – Gas Valve Ventilation System

Sembcorp Utilities UK is a major industrial energy, utilities and services provider to international process industry companies.

FEG Designed, Supplied, Installed and Commission a ventilation system to ensure desired ATEX classification for the area. ATEX is the name commonly given to the two European Directives for controlling explosive atmospheres.

The project included ensuring equipment was suitable for the potentially explosive content of the vented air and locating duty/standby fans on the building roof. Installation contractors had to be managed whilst the plant owner had contractors on site carrying out major works, without affecting the overall programme of the plant owner.

There were significant design constraints due to the array of pipework and steelwork, involved 3D modelling the facility. FEG also incorporated a duty/standby facility to ensure the system would not go off-line due to equipment failure.

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