Designing a Mixer Mounting Frame Around Live Operations
Supporting a Critical Mixer Without Downtime
Our client presented JHT Engineering with a significant challenge: to design and install an entirely bespoke support system for a heavy mixing unit within their facility. The critical constraint? There was no opportunity to take the machine out of commission at any point. This meant the entire process – from the initial survey and design considerations to the final installation – had to occur while the mixer remained fully operational. The existing steelwork supporting the unit was old and corroding, necessitating a solution that could integrate new, robust support without interrupting service.
JHT Engineering's Innovative Solution: Seamless Integration and Strength
JHT Engineering rose to the occasion with a solution defined by meticulous planning and unparalleled precision. Our design was so bespoke and accurate that it allowed the new, robust steelwork to be installed perfectly around the existing, corroding structure, ensuring continuous operation of the critical mixer.
Our approach during the installation phase was carefully choreographed to avoid any interruption:
- New beams were strategically fitted to secure and reinforce the sound existing steel elements.
- The heavy mixing unit was then raised by a minimal amount from its original frame, just enough to precisely insert a new fixing plate beneath it.
- Once the new plate was in position, the mixer was carefully lowered back down, securing it to the new, robust support.
- Only after the new system was fully integrated and supporting the mixer was the old, corroding steelwork safely removed.
- Finally, strength-adding cross braces were installed to enhance the structural integrity, and custom covers were fitted to complete the professional finish.
Our Design Engineer reflected on the precision required:"The challenge of designing a support frame that could be installed around a live, operational mixer was immense. Every measurement had to be perfect. Our bespoke design wasn't just about creating new steel; it was about integrating it seamlessly with existing infrastructure without a single moment of downtime. This required incredible accuracy and foresight at every stage."
The Client expressed their satisfaction with the project's execution:"We tasked JHT Engineering with an incredibly difficult job – supporting a critical piece of machinery without ever stopping production. Their team delivered a solution that was not only expertly engineered but also installed with such precision that our operations remained completely uninterrupted. It was a testament to their professionalism and capability."
Impact: Enhanced Durability, Uninterrupted Production, and Operational Confidence
JHT Engineering's solution provided the client with:
- Enhanced Structural Integrity: A robust, new support system for their heavy mixing unit, built to last.
- Zero Downtime: Critical production was maintained throughout the entire upgrade process, saving significant operational costs and avoiding disruption.
- Seamless Integration: A bespoke design that allowed new components to be fitted around existing infrastructure without conflict.
- Optimized Safety: Removal of old, corroding steelwork replaced by a sound, modern structure.
This project underscores JHT Engineering's expertise in delivering highly customised and complex engineering solutions, even under the most demanding operational constraints.
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