Manufacturing Plant Automation Upgrade
Project Overview
A transformative industrial project modernizing electrical systems and implementing automation for a beverage bottling plant. This comprehensive upgrade included new motor control centers, PLC-based automation systems, energy monitoring, and power quality improvements. The project increased production efficiency while reducing energy consumption and maintenance requirements, positioning the facility for Industry 4.0 readiness.
Industrial automation and electrical modernization for beverage bottling facility.
Project Details
- Client
- Rift Valley Beverages Ltd
- Location
- Nakuru Industrial Park
- Year
- 2023
- Scope
- 30,000 sq ft production facility
Technical Specifications
Challenges
- 1
Upgrading without halting production operations
- 2
Integrating new automation with legacy equipment
- 3
Training operators on new control systems
- 4
Improving power quality for sensitive electronics
Solutions
Implemented weekend installation schedule with rapid commissioning
Designed hybrid control system bridging old and new equipment
Conducted comprehensive training program with simulation
Installed active harmonic filters and power factor correction
Project Results
Production efficiency increased by 28%
Energy consumption reduced by 32%
Unplanned downtime reduced by 65%
ROI achieved in 18 months
"The automation upgrade transformed our operations. Production is faster, more reliable, and our energy bills have dropped significantly. Excellent work by RiftValley."
Michael Otieno
Plant Manager
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