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Bulk storage and handling systems Braby improves efficiency at Reckitt Benckiser plant

Braby, one of the UK’s largest manufacturers of bulk storage and handling systems, has completed a project for Reckitt Benckiser to expand production capacity and efficiency at their Hull production plant.

Bristol-based Braby designed, manufactured and installed an extension to the powder ingredients additions of the facility which manufactures the market leading Gaviscon product.

Braby’s task was to increase throughput of the Gaviscon product and improve the accuracy and consistency of batch measurement, whilst maintaining the stringent level of traceability required in pharmaceutical manufacturing.

Preparation and transit times have been reduced, and the plant’s weighing and transfer capacity has been enhanced by increasing the immediate discharge performance from each of the ingredient hoppers.

Individual material is now separated for weighing and then combined with the entire batch for vacuum transfer. IBatch software integrates with the mechanical capabilities to collect process data and monitor stringent industry requirements for control and accountability.

Due to the availability of a very small shut down window period at the Reckitt Benckiser site, it was crucial for the preparation and FAT (factory acceptance testing) process to take place at the Braby site prior to installation.

With the testing and pre-assembly completed prior to installation, delays to the project’s tight timescale were avoided. Both parties could be sure production could re-start immediately after the shut down period.

John Lee, managing director at Braby, commented:

"Meticulous planning and control were key to the success of the project. Braby completed the wiring and testing of the software controls, and pre-assembled, tested and modified the dosing units, weigh hoppers and discharge equipment at our Bristol premises. As a result, we were able to successfully deliver and install within Reckitt Benckiser’s critical down-time period allowed for the project."

Martin Riddell, project engineer at Reckitt Benckiser, commented:

"The powder handling system modification was a challenging project in terms of complexity, volume requirements and extremely tight implementation timescales. As such, all activities throughout the project were subject to great attention to detail and a focus on the customer requirements.

Braby were 100% committed at all phases of this project to ensure that the design was robust, equipment was manufactured to a high level of quality and the correct resource was available when required. With the combination of Braby’s significant industry experience, our process knowledge and detailed planning from day one, we delivered to specification, on-time and met the requirements of our customers."

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