Project Overview
ETEX Group, a global leader in lightweight construction solutions, embarked on their largest investment to date with the development of a state-of-the-art plasterboard production facility in Bristol. This facility enhances the company’s manufacturing capacity and strengthens its commitment to sustainable construction materials.
Working alongside Wright Engineering, PCS UK Ltd was appointed as the electrical contractor for this ambitious project. Providing comprehensive electrical infrastructure for the plant’s new complex material handling system. Our expertise in electrical installation for industrial and process environments ensured seamless integration of cutting-edge automation and control systems, contributing to the efficiency and reliability of the facility.
Scope of Work
Our role encompassed the complete electrical installation for the gypsum material handling system, including:
Belt Conveyor 1 (BC01)
Installation of electrical supply and control wiring for a twin 160kW drive, facilitating the transfer of gypsum from the Bristol port conveyor to the storage building (110m length).
Belt Conveyor 2 (BC02)
Electrical works for the 70m belt conveyor that transports gypsum from BC01 to BC03.
Shuttle Conveyor (BC03)
Full electrical wiring and control for a 45m conveyor with 90m travel distance, designed to distribute gypsum within the storage hall.
Reclaimer System
Electrical installation for the reclaimer, responsible for retrieving gypsum from the storage hall and transferring it to the ground conveyor.
Ground Conveyor
Electrical infrastructure for the 120m conveyor, ensuring smooth gypsum transfer to the material elevator.
Material Elevator
Wiring and control installation to lift gypsum from the ground conveyor to the calcination feed conveyor, completing the material handling cycle.
Electrical Expertise & Execution
PCS UK Ltd provided a turnkey electrical solution, integrating power distribution, control systems, and lighting throughout the facility. Our team executed:
Full Electrical Containment
to house and protect cable infrastructure
Power and Control Wiring
for all conveyor systems, ensuring optimal performance and automation integration
Industrial Lighting Installation
enhancing visibility and safety across operational areas
Coordination With Wright Engineering
ensuring mechanical and electrical elements operated harmoniously
Challenges & Solutions
Challenge
One of the key challenges was ensuring seamless electrical integration across a large-scale, interconnected conveyor system, which required close collaboration with our mechanical partner as we worked together across the expansive site.
Solution
Our expertise in industrial automation and power distribution, combined with close collaboration with our mechanical partner, allowed us to develop a highly efficient, synchronised control system. This integrated approach was crucial in reducing downtime risks and significantly improving overall operational efficiency.
Project Impact
Optimised Material Handling
Ensuring continuous and reliable gypsum Transfer
Increased Operational Efficiency
Supporting Etex’s sustainability goals with a modern, energy-efficient electrical infrastructure.
A Future-proofed Electrical System
built to support the plants long-term production demands
Why Choose PCS?
With a proven track record in delivering large-scale industrial electrical solutions, PCS UK Ltd stands as a trusted partner for customers across a range of sectors including Aggregates, Pharma, F&B and others. Our ability to integrate complex electrical systems within high-demand environments makes us the ideal choice for companies seeking reliable and experienced electrical contractors.
For more information on how PCS UK Ltd can support your next project, we are here to help.
📞Contact us at sales@pcsukltd.co.uk to discuss your requirements or call us on 01298 79969.
