Objective
Requirement to increase production capacity at the existing site in Manchester.
A new bread line requires liquid services to be installed to the new twin bowl mixing system and steam to the ovens.
Challenge
To create adequate space in the factory for the new bread line to be physically installed.
Establish if the existing liquid process systems can produce the service requirements for the new bread line & increase the capacity to the systems where necessary. All work must be carried out without causing any disruption to the other production lines.
Solution 1 – Site liquid services
PVSL re-routed the existing bakery services pipework. The pipework and bracketry was designed to be manufactured away from the site in sections, this enabled us to wash out the pipework sections prior to installation which was carried out around normal production requirements. The intrusive connections were carried out on the sites normal weekly shutdown periods. (Steam, compressed air, towns water, chilled water, glycol, hot water was among the services.
The FAT , Brine & chilled water pipework was also extended and connected to the new bread mixers.
The required services for the new bread plant were considered at this time, future connections, and isolation valves, were installed into the pipework as part of this re-routing project to keep future intrusive work down to a minimum.
Once the mixers and the ovens were in place we supplied and installed all the service requirements for the mixers and the bread ovens.
Solution 2 – Process liquid ingredients
PVSL extended the existing pipework and provided new liquid process systems to deliver ingredients to the new bread mixers.
New ingredient pumping systems were designed, supplied and installed dedicated to dose 4 x different types of ingredients into the new mixing bowls automatically.
Solution 3 – Liquid Cream Yeast
The new bread mixers require cream yeast to be dosed into the mixers automatically.
The cream yeast is taken from the bulk yeast tanks and pumped around a stainless-steel ring main, each mixer bowl is dosed automatically Teed off from the ring main.
Requirement for the new bread plant is to have its own dedicated cream yeast ringmain so it can be switched on & off & cleaned independently without affecting any of the other bread lines while still sharing the bulk cream yeast tanks.
PVSL designed, manufactured a new independent pumping system that was integrated into the existing cream yeast plant, new state of the art automatic valves and pumps were
Used to automatically select the production and cleaning mode for the new bread mixers.
A new insulated delivery & mixer dosing system was installed as part of this solution completed the project.
