Engineering expertise from Ai Process Systems

Engineering expertise from Ai Process Systems ensures Farrow & Ball’s new flexible water-based manufacturing facility complies with government legislation to cut greenhouse gas emissions

Farrow and Ball, world renowned manufacturer of traditional decorative papers and paints, chose Ai Process Systems to design and install a new bespoke water-based manufacturing facility that is unique in design with significant flexibility to allow the optimisation of product formula without risk of manufacturing process constraint.

John Hackett, Operations Director at Farrow & Ball said, “We are always seeking continuous improvement in the impact our manufacturing processes have on the environment and decided to install a brand new unit requiring a totally bespoke solution.  To be assured of success, we needed to involve an experienced process engineering company in this ambitious project.  We were impressed by Ai Systems Ltd and their proven track record of delivering successful turnkey projects for major industries world wide.”

Ai Process Systems MD, Alan Parry says, “This project provides a new manufacturing facility at the Farrow and Ball Wimborne plant near Poole in Dorset that is fully compliant with the requirements of Climate Change legislation to reduce carbon emissions.  The unique nature of the installation allows total flexibility to continue producing some of the most environmentally friendly products available globally whilst facilitating future growth and range optimisation.”

The Ai Process team designed a manufacturing unit that incorporates process flow techniques that meet the highest possible standards and the latest specifications.  Ai Process met the challenge posed by the requirement to undertake the work within a restricted space and also to take into account likely future phases of planned development. Whilst optimising plant efficiency primary focus remained on allowing ongoing extension of the Farrow & Ball range which scales from very traditional products through to the most modern available.

The Ai Process team, led by Contracts Manager, Jason Waldron, was responsible for:

The design and installation of a new prime manufacturing system supplemented by product let-down and holding vessels
Associated raw materials storage and transfer equipment
Finished base storage tanks
A recipe driven process control system
Associated services such as mezzanine floors, pipe work and electrical installation
Dust extraction system compliant with legislation to control emissions
Work on the first phase of this complex project began in July 2007 and was fully completed in March 2009.   The Ai Process team used their excellent coordination and project management skills to bring the scheme to a successful conclusion within agreed budgets and timescales. 

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