A Long-standing Partnership
Mentholatum is a globally recognised manufacturer of health and wellness products. Their UK facility is a critical hub in the production network, where efficiency, safety, and scalability are paramount. With a long-standing relationship built on trust and results, Mentholatum once again turned to Denca Controls for support in this major upgrade to their tank farm infrastructure.
The Challenge: Supporting Growth with Increased Capacity
As part of their ongoing growth strategy, Mentholatum identified the need to expand their tank farm to improve storage capacity and streamline production processes. The upgrade involved adding a new ethanol tank, a new DEA tank along with the supporting delivery and filling pipework. This was not a response to a shortfall, but a forward-thinking investment in their future operations.
Key to the project’s success would be the seamless integration of new components into their existing control system—all while maintaining day-to-day production with minimal disruption and meeting a tight delivery schedule.
The Solution: Smart Design, Seamless Integration
We drew on years of experience working within Mentholatum’s facility and deep knowledge of their control infrastructure. As their preferred supplier for controls and instrumentation, we were well placed to provide a tailored solution that met both operational and strategic needs. We developed a comprehensive Functional Design Specification (FDS), allowing us to write and test control code offline whilst the automation design progressed. This two-pronged approach helped to ensure efficiency throughout the project.
The new system was configured as a remote I/O extension of the existing PLC system, enabling straightforward integration and long-term flexibility. Regular collaboration was maintained through weekly Teams meetings, involving all key stakeholders—from Mentholatum’s project leads to process and mechanical suppliers—ensuring alignment and strong communication throughout. While the scope and schedule evolved during the project, our collaborative working relationship allowed us to adapt smoothly. When unforeseen equipment requirements emerged, Denca was able to leverage supplier relationships to secure key instrumentation quickly and cost-effectively—something Mentholatum appreciated.
The Results: Capacity, Efficiency, and Confidence
The project delivered significant visible and operational enhancements to the facility. The expanded tank farm not only increases storage capacity but also improves process control and data visibility across the system. By integrating new assets into the existing control framework, the solution enables faster changeovers, reduced downtime, and better resource planning. Perhaps most importantly, Mentholatum now has a scalable infrastructure in place—one that supports their growth ambitions while preserving the efficiency and quality they’re known for.
“From Mentholatum’s perspective, the contribution and support from Denca was as good as I have experienced in any project that I have been involved in. Collaborative, Experienced, Supportive, Flexible and foremost professional.” -Jim Cleghorn, Head of Engineering
Building for the Future
This expansion project reflects not just an upgrade in capacity, but a shared vision for the future between Mentholatum and Denca. With a collaborative mindset, detailed planning, and technical expertise, we’ve helped future-proof a critical part of their operation helping them remain as agile and competitive as ever.
