Adey Steel has completed the fabrication of new Duplex frames for a client in the specialist recycling, renewable energy and waste management sectors.
The client operates some of the best waste technology available in the UK across four sites in Cambridgeshire, Isle of Wight, Milton Keynes and North Yorkshire.
Their site in Milton Keynes, which treats ‘black sack’ waste from households across the Milton Keynes borough, has cut the amount of rubbish sent to landfill to around three per cent while creating enough energy to power the equivalent of 11,000 homes.
However, they were looking to onboard a UK manufacturer who could fabricate a new Duplex frame for their Waste Recovery Park in Milton Keynes while at the same time reduce lead times and increase the lifespan of this critical product.
A dedicated product development team was established at Adey Steel to identify how we could value engineer design improvements utilising the latest in Modern Methods of Construction (MMC).
The team mapped out a brand-new Manufacturing Procedure, including 3D models, in partnership with the client to streamline the fabrication process. They also constructed jigs in the factory to boost efficiency and provide greater levels of accuracy for the sub-assembly of blades and yokes as well as the lower and upper frames.
As part of this exhaustive production process, the water-cooled Duplex frames were pressure tested at six bar to identify any leaks. And, in the rare event of a leak, all repairs were made before being retested until the Duplex frames could hold nine bars for a minimum of 30 minutes.
Only then once the hard face welds were completed, would the product development team sign off on the Duplex frame prior to in-house painting at Adey Steel ahead of main assembly and then final inspection.
Thanks to our innovative way of working, and consultative approach to working with the client at every stage, the average lifespan of the Duplex frames at the Milton Keynes Waste Recovery Park has gone from as little as six weeks to over six months.
As a direct result, the client has also increased the cost effectiveness of the Duplex frame and significantly reduced downtime. Adey Steel is also able to offer the client a next working day delivery option in the event that the Duplex frame develops a fault by keeping the unit as a stock item at the company’s headquarters in Loughborough.
If you would like to discuss a future project with our team, please call Adey Steel on 01509 556677 or email [email protected].
