Tissue Paper Factory Redevelopment

Tissue Paper Factory Redevelopment
Case study

Start date: October 2023 | End date: March 2024 | Industry sector: Paper Manufacture

The Challenge

Our customer, a leading manufacturer and supplier of hygiene paper products, committed to a significant investment in new premises, to accommodate their future growth and to expand their operational capabilities. The site, previously occupied by a print manufacturer, required a complete transformation to create an environment that was fit for the purposes of our customers’ needs.

Before any redevelopment could begin, all existing machinery, legacy plant and wiring was removed. A new factory layout was carefully designed to house the new machinery and associated equipment, tailored specifically to meet the production processes and operational requirements of our customer.

The project included the incorporation of new switchboard’s, power, lighting containment and cabling, to support and suit the new manufacturing production requirements. Lighting was reviewed using Robus solutions, to ensure the optimal illumination, throughout the facility was achieved, to provide the correct level of lighting to deliver a safe, efficient and productive environment.

As is typical when repurposing an existing industrial site, there were challenges, including how the new machinery could be positioned within the space and the electrical installation could be installed in line with time frames and machine installation requirements.

Our Approach

The initial stage of the lighting re-design was to undertake a site visit, to establish factory structure, roof height, site orientation (to understand natural light) and surrounding area.

Layout of machinery and operational work patterns were discussed to ensure all requirements were substantiated and understood. With all facts gained the best electrical layout and lighting system could be designed to suit the new factory layout and operating requirements.

Forward planning of the layout and installation of the containment was completed, to accommodate the necessity to have this installed prior to the installation of all the machinery.

It was essential that a plan was created, as this provided the installation schedule to manage the initial access to install containment and cabling to the new machinery, before the new machinery was delivered and positioned. It would have been extremely difficult to run the required containment and cabling etc., once the machinery was in place.

The Solution

Lighting has a huge impact on how people work within a space and their safety, productivity and wellbeing. It was imperative that the new lighting provided the correct lux (brightness) levels, to meet these needs and enhance the working spaces.

Working with Robus, the electrical layout and power requirements were discussed and calculated, along with the operational process requirements, to establish where and what type of lighting would be best suited and needed.

Power supplies were installed to two new distribution boards to meet the needs of the new lighting and power installation.

To provide sufficient light distribution UFO style Sonic 4 LED High Bay light fittings were decided upon to use throughout the factory. These provide a directional light, which has a huge impact on the working environment for the operators. They create a bright light distribution, without creating glare.

LED lighting is significantly more energy efficient than the old traditional Sodium Vapour/ Metal Halide lighting and meet the energy efficiency targets. This energy efficiency will provide considerable cost savings for this facility.

Lux levels were checked to ensure the correct brightness was provided in all the different areas, which is a key consideration for factories with a high roof structure.

Looking at the orientation of the building, natural light was also considered to work in conjunction with the design and layout of the lighting system.

In the event of power failure, emergency lighting was incorporated into the lighting design. This is a standard requirement, to support the escape and identify firefighting equipment and exit routes clearly, in the event of a power failure or emergency.

Trimble software was used to calculate the cable requirements. This ensured the correct cabling was used to meet the amperage of the machines.

Working to the planned schedule, Delta installed the cable containment in accordance with the delivery of the machines, so these were all in place beforehand. The cabling for the machines was supplied from our new MCCB panel and Distribution Board, which were installed during Phase 1 of the installation.

With such large scale project we needed to work with the various trades on site, to ensure we coordinated where we needed to be working, alongside other installations that were in progress during this large redevelopment.

Value Delivered

The installation will have significant impacts for this new facility, which includes:

Reduced energy consumption.

Maintenance reduced, as new LED fittings have a longer life.

A lighting system that is compatible for factory and workspace.

Emergency lighting system, in the event of power failure, to safely guide people along walkways to emergency exits.

Vastly improved and updated lighting system, that provides an excellent light quality work environment.

Reduced costs, improved energy efficiencies and carbon savings.

Choosing the correct lighting system, supported by a safe and effective electrical control system will foster a stimulating and effective environment for the workforce.

At Delta Rock we pride ourselves on working with clients to understand their needs from the outset, to ensure the best electrical infrastructure design and lighting system is adopted and installed to suit all the operational needs of the business and operators.

Tissue Paper Factory Redevelopment

The Challenge

Our Approach

The Solution

Value Delivered

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