Case Study

Lead Oxide Transfer System - Bulgaria

Duration: 24th Novemeber, 2008 - 11th May, 2009

This was an interesting materials handling project for our team that came in on time and within budget. Mechtek were initially asked to carry out a pre-project cost and design review for our client, an international battery manufacturer, to see if existing plant in the UK could be re-engineered and relocated to a group site in Bulgaria creating a new lead oxide transfer system.

This feasibility study led to the designs and capital project being approved from our client's US head office. Working to tight timescales Mechtek had to co-ordinate the project and procure services and supplies from different countries, ensuring all documentation was translated correctly and language barriers overcome. The design process challenge was to transfer grey lead oxide from an existing Barton oxide mill into production lines within the Bulgarian site. This was a key process to create the battery paste required in normal battery manufacture.

This project was a complete turnkey operation involving the modification of existing plant, installing new plant and covering all MEICA aspects up to commissioning stage. Mechtek eventually shipped all plant and equipment, including screw conveyors, blowing lines, pipework, filter unit and access structures across the channel to meet up with the mechanical and electrical engineering teams. A bucket elevator was sourced from Bulgaria and a vac line and other pneumatic handling components brought in from America.

Project Manager John Lloyd recalls "We started the installation in mid-March and were ready to commission on the last day of April. In that time we put in the three large UK silos, 90 tonne load cells and filter unit, all air lines, actuator sleeves, rotary valve, silo platforms/equipment. On projects like these it is essential that you source the best labour. The job for our 5 strong Bulgaria team was made so much easier by the quality of the local engineering company we used to work on the conveying pipe work and air line installations."