Introduction
Duerr’s is a well-established UK food manufacturer and as a beloved heritage brand. Maintaining efficiency and reliability across their manufacturing processes are essential. We’ve been a long-term and trusted automation partner to Duerr’s throughout our 30 years of operations. As a result, Denca consistently supports their site with electrical and instrumentation expertise. Furthermore, with a trust based on collaboration, we have developed a deep understanding of the way they work. We have built strong relationships with on-site teams. These relationships enable us to deliver solutions that align with both production and operational priorities.
The Problem
Duerr’s proactively identified an opportunity to improve the longevity of a legacy, yet critical, production machine. While the system remained operational, its condition and configuration posed challenges for future maintenance and scalability. This would be a particular issue in the event of an unexpected failure.
The Duerr’s team recognised the importance of acting before issues arose. Consequently, they sought to relocate and modernise the equipment to better meet current production demands. Given the production-critical nature of the machinery, the project required careful planning to ensure minimal disruption to ongoing operations.
Denca’s Solution
We undertook a comprehensive site survey to fully understand the existing installation. Our team then developed a safe and efficient approach to the relocation. This included:
- Tracing and identifying all cabling and instrumentation
- Backing up original software
- Producing a complete, updated design and drawing package
Working in close collaboration with Duerr’s operational and engineering teams, we developed a detailed and practical plan tailored to tight production timelines. Additionally, extensive documentation was created covering motors, instrumentation, cabling, and termination points. This all ensured reconnection could be completed quickly and accurately.
The system was carefully segmented into manageable sections to enable relocation. All associated control cabling, mains power, network infrastructure, and air lines were rerouted or replaced as required for the new location. All solutions were designed and delivered in-house, with continuous communication maintained throughout the project to ensure alignment at every stage.
Crucially, all work was carried out seamlessly within an active production environment, demonstrating our ability to integrate safely and efficiently on a live site without interrupting operations.
From our customer….
"Denca have supported us for many years, and this project was another great example of why we value that relationship. The relocation and modernisation of a critical production machine required careful planning, technical expertise and close collaboration to ensure our operations were not disrupted. Denca managed the project professionally from start to finish, working closely with our teams and delivering the relocation, testing and commissioning within our production requirements. Their attention to detail and ability to work effectively within a live manufacturing environment gave us complete confidence throughout.We now have a more maintainable and future-ready system, delivered with the quality and reliability we have come to expect from Denca." Paul Parker, Engineering Manager
The Result
By all accounts, the project was completed successfully within the defined timeframe, meeting all production-critical deadlines while maintaining continuity of operations. The machine was reinstalled, reconnected, and commissioned in line with the FDS, significantly reducing downtime during the transition.
All systems underwent rigorous testing, including insulation resistance testing of motor cables, full control cable verification and functional testing of the complete installation. Instrumentation, including load cells, were recalibrated and certified, ensuring accuracy and reliability in the updated system.
Software modifications were implemented to reflect the revised configuration, followed by comprehensive I/O checks and full system validation prior to returning to production. New certification and commissioning documentation were provided across HMIs, PLCs, control panels, and instrumentation.
The result was a fully modernised, more maintainable and future-ready system. By combining detailed planning, technical expertise, and close collaboration, we enabled Duerr’s to enhance their production capability through a proactive and strategically executed upgrade.