Manufacturing

Sectors

Maximising potential, minimising footprints and understanding our client.

RPS is one of the leading consultancies for designing energy efficient facilities to house complex manufacturing processes. Liaising closely with process engineers to understand the operational and commercial drivers in the earliest stages, our project teams are highly skilled at co-ordinating the crucial interfaces between the process equipment, the building layout and structure and the building services to ensure the completed building accommodates the installation of all machinery and plant efficiently and effectively.

Our integrated teams are dedicated to maximising development potential and minimising carbon footprints in increasingly challenging sites. We have designed major facilities in the food processing, printing and gas production industries, including newbuilds, complex extensions, refurbishments and national roll-outs following company restructurings.

Emphasising buildability, our designs are simple in concept, economic to construct and cost effective to maintain, with inherent flexibility to accommodate changing process requirements.

RPS has been the winner or finalist of 41 awards for distribution centre design since 2002, including a prestigious award in 2009 from the Industrial Agents Society recognising the contribution we had made over 27 years in the industry.

Our services include:

Architecture

Building Services Engineering

Civil & Structural Engineering

Ecology

Environmental Assessment & Management

Landscape Architecture & Management

Planning & Consents

Project Communications & Stakeholder Engagement

Transport & Infrastructure.

Case Studies

Aerostructures Assembly

Aerostructures Assembly & Manufacturing Facility, Broughton

Airbus UK

RPS provided Mechanical and Electrical Engineering designs for a 900,000ft2 facility to manufacture wings for the A380 Super Jumbo Aircraft.

RPS as part of a project team, developed the design of the facility in close co-operation with the manufacturing team, commencing at a stage when even the design of the wing component to be manufactured had still to be finished.

The facility houses an Energy Centre with four gas fired CHP plant engines. The CHP plant was designed and procured under an ESCO and RPS fully liaised with the client and ESCO team to integrate the CHP plant with the overall factory design. Waste heat from the CHP plant is utilised to provide heat to the ‘paint shop’ adjacent to the Energy Centre to maximise the ‘utilisation factor’.

The projects key features included:

Central CHP Plant

Extensive Natural Light

Mixed Mode Ventilation

Heat Recovery to Air Handling Plant

Heat Recovery from Compressor System.

London Taxi Assembly Facility

Asda Supercentre, Milton Keynes London Taxi Assembly Facility, Coventry

The London Taxi Company (LTC)

This new facility is LTC’s new headquarters housing a substantial R&D department, a supply chain team, global sales & marketing as well as the central administrative functions necessary to support the assembly operations. The assembly operations on site have been tailored to low volume production using skilled labour and the operations are clean in nature, generating nothing significant by way of noise pollution or air emissions.

The facility is approximately 21.5 acres, offering a total of 25,000m2 of floor space with over 20,000m2 in the main production/assembly hall and nearly 5,000m2 in ancillary offices, reception/showroom and staff welfare facilities.

DBK were acquired by RPS in April 2016.

Motor and Generator

Motor & Generator Manufacturing Plant, Rugby

Quartzelec

RPS, as part of a project team, designed a new build, 94,000ft2 flagship manufacturing facility around Quartzelec’s process equipment.

The facility now houses one of the largest, state-of-the-art, load test facilities within Europe.

The sloping site and a metre deep band of soliflucted material was a challenge. This was excavated and re-compacted to achieve the strict settlement criteria required for the building.

The foundations were designed in accordance with Eurocodes 2 and 7 resulting in some savings in material costs due to the multiple imposed loads applied to the foundations and the ground conditions to house a 70 tonne over-head travelling crane and a 16x5m milling machine.

RPS provided a multi-disciplinary service for the project including Civil and Structural Engineering, Highways, CDM Co-ordinator, Flood Risk and Acoustics, Noise & Vibration. Continued communication and collaborative working methods across the project team contributed massively to the success of this project that was delivered on time and budget.

Project Hal

Project Hal, Printwork Facilities, Broxbourne and Knowsley

News International Ltd

After completing Masterplans and Planning applications, RPS provided Architectural design and Construction services for two, new, printworks for News International Limited.

The new print facility at Broxbourne required Architectural, Lead Design, Civil and Structural Engineering design services to custom design the facility to house six highly automated, full colour broadsheet printing presses.

The new print facility was sympathetically designed around the 30m high press hall with a gross internal floor area of 67,000m2 over four floors and incorporates associated offices, goods in/dispatch area plus storage and welfare facilities. The 15.5ha site also has a separate batching/packaging facility, a new electricity substation, standby generators, sprinkler tanks/dampening water tanks and a pumphouse.

Our specialist architectural expertise was pivotal in gaining planning approval. Specifically, in minimising the facility’s physical impact and the utilisation of innovative solutions to minimise the impact on the surrounding area.

RPS also provided Architectural and Lead Designer services for the 191,000ft2 printworks extension at Knowsley, to house new state-of-the-art printing presses. Our architects worked with NIL’s teams to integrate the extension whilst minimising disruption to the client’s daily operations.

Project Orange

Project Orange, Somerset

Gerber Foods

RPS provided design services for the phased development of a new processing plant for one of the largest drink manufactures in the world.

RPS provided Architectural, Civil and Structural services to design a facility that exceeded British Standards for a food manufacturing facility. The end result was a food-safe, dust free, chilled, hygienic and low maintenance environment.

RPS’ highly skilled project team co-ordinated the crucial interfaces between the building layout, structure, building services and the process equipment by liaising closely with the plant engineers to ensure the completed facility accommodated the installation of all machinery and plant efficiently and effectively.

Our solutions included dust resistant designs, stainless steel finishes, no fibrous materials or glass within the production environment and bespoke stainless steel effluent drains for varying sugar / acid levels.

The project, which included the design and construction of 56,000 m2 of new facility, was built over three phases, with phase 1 becoming a live operational plant while the subsequent phases were developed.

The projects key features included:

Central CHP Plant

Extensive Natural Light

Mixed Mode Ventilation

Heat Recovery to Air Handling Plant

Heat Recovery from Compressor System.

Waterside Mill

Waterside Mill, Cheshire

Disley Tissue Ltd

RPS produced Transport evidence and secured the Environmental Permitt in support of a proposal to expand an existing manufacturing plant.

Increasing production of tissue to over four times the existing capacity required a substantial variation to the Environmental Permit application. RPS completed Air Dispersion Modelling and completed a Stack Height Assessment in addition to full BAT Assessment, H1 and Environmental Risk Assessment and completed an Application Site Condition Report.

Following consultation with the relevant Local Authorities, RPS also produced a Transport Statement, Travel Plan and Transport Chapter within the Environmental Statement for submission as part of the planning application.

The transport evidence submitted calculated and assessed the impacts resulting from the additional vehicular trips generated by the realisation of the development proposals, incorporating a car parking accumulation exercise and junction capacity assessments.

The impacts of the proposed development were assessed against the increased levels of severance, delay, amenity, intimidation and accident potential resulting from increases to the levels of traffic generated by the site.