Intro
PEMEC delivered the complete construction package for the upgrade of a solids handling process at a UK fatty acid and derivatives producer, whose products include additives for polymers, inks, lubricating oils and paper. The works ran from February to June 2026, from demolition through to mechanical completion and commissioning support, inside a live manufacturing facility.
Project Objective
The existing solids handling process suffered from low throughput, product quality issues, ageing equipment and reliability concerns. The project replaced the existing conveying, sieving and dosing systems with modern equipment, including a new Flexicon conveying system, Russell Finex vibratory sieves, upgraded silica and zinc stearate dosing systems, and associated structural steelwork, pipework, electrical and instrumentation.
The main objectives were to:
- Restore the plant to its design production capacity
- Increase throughput by removing process bottlenecks
- Improve product quality by reducing agglomeration, contamination and compaction
- Replace ageing and unreliable equipment
- Improve the reliability and accuracy of silica and zinc stearate dosing
- Enhance operator safety through improved dust handling, explosion protection and easier maintenance access
- Improve the overall efficiency, maintainability and sustainability of the process
Project Scope
PEMEC was responsible for the complete construction package, which included:
- Demolition and removal of the existing conveying, sieving, dosing and associated mechanical systems
- Fabrication and installation of structural steel, platforms, pipe supports and roof modifications
- Installation of the new Flexicon pneumatic conveying system and Russell Finex vibratory sieves
- Installation of the new silica and zinc stearate dosing systems, including all associated process equipment
- Installation of compressed air, nitrogen and process pipework, with valves, supports and pressure testing
- Installation of electrical containment, power, instrumentation and control systems
- Mechanical testing, commissioning support, certification, as-built documentation and final handover
Approach and delivery
The works were delivered inside a live manufacturing facility while minimising disruption to operations. Demolition, structural steel, mechanical, piping, electrical and commissioning activities were coordinated to a tight programme, with new process equipment and pipework installed across multiple floor levels in restricted working areas. Existing plant was safely removed and replaced, with the new systems integrated into the existing infrastructure.
The site was a hazardous environment involving combustible dusts, working at height and strict permit-to-work requirements. Logistics, lifting operations, material deliveries and multiple specialist subcontractors were managed to support the programme, with close collaboration with the client throughout.
Follow-on work has since been secured with the same client, including a new heat exchanger and pipework installation and an ammonia recovery project.
Outcome
The installation, testing and commissioning of the new solids handling systems has provided the client with a safer, more reliable and maintainable facility that supports improved operational performance and long-term production objectives. The project was delivered through effective planning and close collaboration with the client and specialist subcontractors, with minimal disruption to the client's operations.
Lessons learned
The key lesson from the project is that successful delivery of complex industrial projects depends on thorough planning, effective communication, collaborative working and proactive management.
Recommendations for future projects
- Engage all stakeholders early during the design phase to identify constructability issues, access constraints and service clashes before construction begins
- Carry out detailed site surveys and 3D model reviews to reduce design changes and minimise rework during installation
- Procure long lead-time equipment and materials at the earliest opportunity to protect the construction programme
- Continue regular coordination meetings between the client, designers, contractors and subcontractors to support effective communication and timely decision-making
- Develop comprehensive construction, lifting and logistics plans before mobilisation, particularly for projects within live operational facilities
- Adopt a phased installation and commissioning approach, allowing progressive testing and early identification of issues before final handover
- Maintain a strong focus on health, safety, quality and environmental performance through regular audits, toolbox talks and behavioural safety initiatives
- Capture and review lessons learned throughout the project to drive continuous improvement and share best practice across future projects
- Maintain accurate quality records, inspection reports and as-built documentation to support commissioning, handover and future maintenance
- Continue to build collaborative working relationships with clients and supply chain partners