Picture 1:Factory start up 2007-2008

Project included possible locations evaluation, premises renovation planning, component negotiations, layout drawings, mechanical, electric and component drawings. One new automatical line from recycled components and a new curing oven was designed. Installtion management and factory Turnkey services.

With small resources, high results

Before this place was selected, we were as a technical advisor to choose suitable new factory location. At that point customer had less than 10 months to move their existing factory to an new location. Also production volume was needed to increase because from old factory production volume was too low . Actual design project started with 'new' space condition evaluation: ground, walls, roof and facilities. After accurate dimensioning and documentation we made plans to renovate building. During renovation recycled components were re-located first on a CAD drawing to find effective material flow. A new automation line and curing oven was designed. Automation line components where an old bakery bread baking conveyor. After 8 months from entering the premises new factory was running. Picture 1 down/up views refer to the same viewing angle before and after factory start up.

Picture 2:New factory production Turn key day was 14.1.

Finally the production started one week later. Russians who were appointed to start pre-treatment line left factory before New Year. Essential line for the hole production did start after we provide our Turn key services!

Click small image to see the hole pre-schedule plan for electricity.

At Russia, Russian technology projects are required according local reculations. Technology projects contents and forms are standardized. Round stamps are very important.

Picture 3:Consumer point power calculations and supply cable dimensioning

At this point small adjustments are possible.

Click small image to see the hole power calculation.

At the first stage the factory power was not as required and the option of diesel generator energy was needed. At firts that was only an backup option but because we were aware about old factory transformer technology, two additional cross switch cabins for generator energy were designed by Sime.

Picture 4:Transformers and other energy supply

Before final selection, power supply quality must be checked.

Click small image to see the hole plan.

This factory did have steam option which was used for input air heating.

Picture 5:Power distribution cabin designs

We used old and designed new cabin for this project.

Click small image to see the distrubution plan.

Power distrubution was designed so that ventilation power was connected to two main production lines. At that point Russian HVAC desings where not started because tight schedule.

Picture 6:Previous factory layout from 2002

Material flow and required technical equipment should be positioned to the factory layout.

This layout was only 5 years in use!

Layout planning is vital for the new factory. Line re-organizations are tasks that no end customer will pay about them. Layout should be well evaluated before any final desissions are made.

Picture 7:Factory layout 2008

Our designs cover also yard renovation and transportation facility designs.

This is a final layout with every details.

When recycling old components, they must be dimensioned and equipment technology must be resolved before final layouts can be made.

Picture 8:Line details from north->south / up->down

Tubing and cabeling need documentation that ensure problem free work flow.

It's easy to develop and purhase new equipment when production space is under control.

We design factories generally with a accuracy of 1 millimeter. When recycling a factory, the old building must be first documented so that new constructions may be located. See detail drawing right corner where crane track support brackets horizontal I-beams are located through roof one supporter (two supporters on the drawing).

Picture 9:Power supply points according machinery and working places

Mechanical and electric designs are on the same drawing but on different layers.

It's important to check also used general purpose equipments to enable correct power supply sockets.

Power supply calculations are based on resistor and motor designed power consumption. Because old factories may have technical disablities on existing transformer rooms, switch over other paralell transformer power supplies has been done to ensure critical minimun production.

Picture 10:Pre-process automated heating and process tank control cabin

Cabin manufacturer is typically local company when cabin size may vary.

Normal relay automation controls like fluid level detector control heating. Process overall control in on PLC and if there is a computer, that is needed mainly for quick error detections and for mayby to process variation controls. Variations may be product number based or process transfer path adjustments. Then a simple switch do not allways serve the same way as computer HMI text declarations.

Picture 11:Moving machinery cabling at Russia

Designer must understand what kind of cables recycled equipment needs and how cables are supported to ensure long expected life time.

Propper crane flat cables may require extra work especially at Russia.

When automation componets are designed and cabelig diagrams are done, PLC programs and HMI interface should be designed carefully.