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Accurate project design and resource efficiency
One of our largest pharmaceutical customers has initiated a project involving the reconstruction and replacement of the refrigeration plant, ventilation systems, BMS and electrical supplies at a 10,000 m2 factory.
As part of the project, the old ventilation systems will be lifted out of the 5 technical rooms in the factory and replaced with fewer and larger plants on the roof. Simultaneously, the solution will provide the customer with modern, energy-efficient equipment and free more space in the technical rooms.
At the same time a new refrigeration plant will be established, a number of old building services on the roof will be demolished, and pipes and cables will be run from the new plants down to the technical rooms. One of the challenges is to stay clear of existing refrigeration systems, piping and roof light installations, etc.
Due to the complexity of the project, traditional measurement and data registration methods would have been highly time-consuming. The use of 3D laser scanning and modelling has helped to ensure a quick and smooth process. A detailed mapping of existing and future building services has facilitated the planning and coordination processes significantly, resulting in reduced costs in terms of time and money.
3D scanning and modelling in practice
The task has been carried out in cooperation with a subcontractor specializing in laser scans. Using scans from 15 measuring points, the entire roof and all the building services have been mapped down to the smallest detail (+ / – 2 mm) in a so-called point cloud. The laser scanner also took visual images for 3D modelling.
The roof and all the building services were mapped in a point cloud based on approx. 15 measuring points.
By converting data from the photo images and the point cloud into 3D objects such as roofs, hoods, refrigeration and ventilation plants, we created a complete 3D model of the building and the roof showing both existing and future building services. It was then easy to design the new plants on the roof while taking the existing facilities into account.
Scanning facilitates prefabrication
3D scanning and modelling was also used on a technical floor of approx. 1,000 m2 where existing ducts to the production areas will be connected to the new manifold and ducts running from the roof. This task required a scan head with a finer resolution, and accurate 3D scans have made it possible to prefabricate ducts and adapters externally so that the building services can be implemented quickly with minimal disruption to the production.
Technical floor with the roof removed. Grey building services are pre-existing, coloured building services are new.
Laser scanning pays off
While 3D laser scanning is a resource-intensive method, the investment can pay for itself in man-hours saved on measuring, registration and design processes. The method ensures that all essential data are registered quickly, efficiently, and with great accuracy. It shortens the process between idea and implementation, making it easier to plan and coordinate the work in the project design phase. At ALECTIA, we have positive experiences in using the tool, which is more and more commonly used.
From conceptual design to site supervision
As full-service consultant, ALECTIA has handled the project all the way from conceptual and basic design to detailed design and tender. In the ongoing implementation phase, which is expected to run throughout 2014, we are responsible for construction management, security management and technical supervision.
Through most of the 1900s, all animals for slaughter had to pass through the Meatpacking District of Copenhagen where they were checked by veterinarians, slaughtered and cut up before being distributed to the butchers in Copenhagen. Today, the Meatpacking District has developed into a cultural centre with galleries, restaurants, clubs, bars, schools and other creative companies. The renters still include companies which produce and sell food, and the need for cooling and freezing remains – now also for purposes such as comfort cooling, server cooling, etc.
The White Meatpacking District, which is located next to the older Brown Meatpacking District, opened in 1934. The place was equipped with a refrigeration plant which was ultramodern at the time and allowed for safe and hygienic handling and storage of carcasses and meat. However, as the existing refrigeration plant uses ammonia as refrigerant, which poses a toxic risk to the surroundings in case of ammonia emissions, an extensive environment protection project is in progress.
Copenhagen Properties put the project, with a budget of DKK 49 million, out for tender in a competition won by ALECTIA in 2013. It is a project in which our cross-disciplinary competencies are truly put to use.
“It is an exciting task with the particular challenge that the White Meatpacking District is totally preserved,” Project Manager in ALECTIA Claus Lund Poulsen explained. “It means that there are certain requirements for the appearance of some of the building services in terms of design and colour in order to maintain the original aesthetic expression.”
Ammonia replaced with glycol
The Municipality of Copenhagen’s Centre for Environment has issued an enforcement notice that the refrigeration plant in the Meatpacking District must be rebuilt to reduce the risk of ammonia emissions in case of an accident. A number of specific conditions relating to the refrigeration plant and the technical supply section in the Meatpacking District must be remedied before the end of 2014 for the Meatpacking District to remain open.
Ammonia has been widely used as a refrigerant because of its thermodynamic properties. However, it is also associated with great risks, as ammonia is highly poisonous to humans and nature.
The refrigeration plant will therefore be rebuilt so that the use of ammonia is limited to the distribution tunnels underneath the Meatpacking District as well as the actual technical supply section. In those parts of the cooling system, which are the responsibility of the renters, ammonia is replaced with glycol and water which are not equally dangerous.
ALECTIA facilitates all project phases
ALECTIA manages project design, tender documents, contracting and communication with all stakeholders as well as the general project management. During the implementation phase we are furthermore responsible for technical inspection, construction management, safety management and authorities processing.
For the rebuilding project, ALECTIA draws on a wide range of special competencies across our divisions. About 12 specialists are attached to different projects and contribute expertise including:
The refrigeration plant rebuild is currently well underway, and the works are divided between two contractors.
Copenhagen Meatpacking District anno 1930.
Increasing the productivity and optimising the profits require in-depth knowledge of each individual part of a production process – from the acquisition of ingredients to the presentation of the finished product in the stores. ALECTIA Food’s specialists have many years of experience with and knowledge of how to optimise different productions.
Meat producer saves USD 120,000 per week
Recently, we helped a large international meat producer save about USD 120,000 per week at one of its large plants in North America producing approx. 350 tons of meat per week. The meat producer asked ALECTIA to consult on a project to optimize the production and increase the yield.
Based on the findings in a plant audit, ALECTIA came up with several proposals for trimming and optimizing the production to create a large saving for the company. For instance, we advised the client on how to optimize the process the meat goes through before the final slicing and packaging, which included a suggestion for improving the meat trimming process in order to optimize the degree of utilisation.
The producer implemented ALECTIA’s ideas and achieved a saving of no less than USD 120,000 per week. Thus, the producer achieved a high return on its investment in ALECTIA’s consultancy.
By combining our process technical competences with an in-depth business understanding and knowledge of the industry, ALECTIA helps clients ensure maximum production efficiency. We offer a series of production-optimizing initiatives:
Creating a productive working environment is about adjusting the three primary factors that affect your employees’ ability to work effectively: leadership, health and safety. We believe that the employees deliver the results and that an integrated approach increases the productivity in a workplace.
We know that investing in a good working environment contributes to maintaining and improving a company’s productivity and image. We also know that providing useful occupational health and safety advice is not just about strong skills but requires a thorough knowledge of the market in which our customers operate. Based on our extensive trade knowledge we can provide advice that goes straight to the core of our customers’ challenges. We transform ideas, thoughts and strategies into concrete initiatives that create positive results on your bottom line.
ALECTIA offers a variety of services ranging from advice on the physical and psychosocial working environment, acoustics and noise, chemicals and biological hazards, health and safety, stress and well-being to management training and organisational development.
We are licensed by the Danish Working Environment Authority.
Our position as leading adviser on production facilities and process equipment requires both in-depth knowledge of the industry and an understanding of the client’s end product and production processes. ALECTIA has extensive knowledge on the production processes specific to the industrial segments we work with. Our experts specialise in planning and designing process facilities for anything from raw material reception to processing, production, bottling/packaging, logistics and storage.
We provide engineering advice during all process phases – from clarification, analysis, design and planning to tender and project realisation. We review new plants and advise on facility expansions, refurbishment and upgrades.
Combining our process engineering skills with a deep business understanding and specific trade knowledge we help our clients focus on business-critical areas. Our consulting approach also ensures that projects live up to all quality, financial viability and production efficiency requirements.
We help our clients find the right technical solutions and advice on the formulation of technical specifications, the choice of solution principles and the development of tender and project documentation which forms the contractual basis for ensuing construction activities.
We draw on a wide range of skills and are experts in core engineering disciplines such as structural, HVAC and electrical engineering coupled with construction management and owner representative services. Furthermore, we offer specialist services in areas such as tender management, building automation, indoor climate, building physics, material science and engineering as well as fire engineering.
Our ambition is to always be innovative and deliver projects and results which create value for our customers, ALECTIA and the society we are part of.
Our environment, energy, water and climate solutions are always based on sustainable consultancy. For instance, we advise the industry on energy and CO2 reduction and compliance with environmental requirements, and we are leading within cooling solutions for process and industrial companies as well as hospitals.
We combine the newest technology with years of experience when advising on water at all stages, from nature protection and soil and groundwater contamination to wastewater management and drinking water distribution. We advise during all project phases, from clarification, analysis, design and planning to tender, construction management and supervision.
In the climate area, increasing greenhouse gas emissions have caused climate changes which pose still greater challenges. Heavy rain incidents lead to rainwater and wastewater floods which cause traffic problems and damage to residences, businesses and plants. Combined with worn-down wastewater systems this increases the need for investments in new climate adaptation solutions. ALECTIA’s experts can help with planning and executing all kinds of climate projects, always going for viable long-term solutions to reducing greenhouse gas emissions and remediyng the damaging consequences.
Our clients are utility companies, local governments, the state and large Danish and international process and industrial companies.
ALECTIA will be at the Brau Beviale 2014, and we look forward to seeing you there in Hall 7, stand 521.
ALECTIA Brewing Benchmark Club
This year, ALECTIA has launched a new worldwide benchmarking scheme – the “ALECTIA Brewing Benchmark Club” which offers breweries a unique opportunity to improve their business. At Brau we will present the initial results of the benchmarking. And of course – sign up new participants who are interested in learning how to improve their business.
Audits and Condition Evaluation: Based on our vast experience of optimising production plants, ALECTIA carries out audits with the goal to reduce our client’s operational costs, evaluate the current condition and identify the needs and timing for investments. As an example, we have carried out a large number of utility audits, typically identifying 10-30% savings potentials on our client’s energy and water usage.
Business Cases: We can support your strategic decisions with facts and financials. ALECTIA’s business cases visualise and compute all benefits and risks related to your development, enabling you to make the right decisions for your business.
Optimisation of OPEX: With the ALECTIA Opex Optimus™ approach we can offer you lasting operational improvement and cost reductions. We can work with your team on known and new improvement areas and make sure that the implementation is speedy and well designed. We put our final fee at stake on achieving the agreed outcome! ALECTIA’s audit teams have identified operational cost savings of EUR 1.9 per hl produced on average.
Production Structure Analysis (PSA): Is your overall production structure optimal or should you concentrate the production on fewer and larger plants? If so, which plants should be closed and should other plants be expanded? Or should you build a greenfield plant? These are all questions that the ALECTIA PSA will answer by identifying the optimal long-term production structure when evaluating the economic and technical consequences of the different scenarios.
Logistics: ALECTIA is market leading within optimisation of logistical and packaging solutions in a number of industries. Through innovative solutions for optimising processes, organisations and systems, we boost your competitive power by optimising your supply chain, and thus increase the productivity of your business.
Master Plan and Dynamic Master Plan: We can create a master plan that translates your strategy into a solid plan for your production assets. You can choose between the detailed Master Plan or the Dynamic Master Plan which gives you the ability to continuously plan your CAPEX needs in a rolling scenario.
Sustainability: Changes in climate and access to natural resources challenge strategic assumptions, technology, and behaviour in the beer and beverage industry. Establishing your green production of the future means defining your sustainability ambition and adopting a strategy for going from best practice of today to next practice.
ALECTIA supports your journey from defining strategies and assessing risks, to executing projects with the goal to improve your environmental footprint and lowering your costs. ALECTIA can offer the advantage of taking a 360 degree view on sustainability including the indirect and direct consequences on the product quality.
From idea to operation: At ALECTIA, we support our clients from the very first ideas through to operation, ensuring that today’s plants are designed to meet tomorrow’s requirements.
Project Management: ALECTIA’s project delivery model is a client-focused delivery tool, giving you an overview of all the project phases. The model ensures a systematic and professional approach – from analysis to operation.
Investment in production – CAPEX: No one understands better how to plan, design and execute CAPEX projects than ALECTIA. With more than 50 greenfields and large CAPEX expansions under our belt, we can provide you with high quality advice on all matters regarding your investment. Whether you are planning a greenfield project, a major upgrade of your existing plants, or migrating sites, ALECTIA helps you make the right decisions from day one. Our CAPEX project methodology and tools guide you safely through all phases of your project, from master plan through basic design, tendering and contracting to test and commissioning.
Upgrades of existing plants – brownfield: Modification or migration of existing plants are often the most complex operations. It is necessary to know the details of the existing facilities in order to change them – and keep the production stable during the changes, while securing no disruption of market supply. ALECTIA’s consultants have modified a large number of plants around the globe – and in many different setups. Based on our expertise we provide you with experience and knowledge of routes to go, and we ensure that you keep meeting the production targets and other demands to your plant.
Improve your performance: ALECTIA provides numerous services and technical assistance to your day to day operations. We have in-depth know-how, as many of our employees are engineers with a background in beverage and food production.
Plant automation: From analysis to design and execution, ALECTIA develops and implements automation concepts. Our automation solutions focus on securing smooth and efficient production. To fully support your business, we integrate process equipment with manufacturing execution systems (MES) and enterprise resource planning systems (ERP).
Utilities, Water and Energy: We are experts within water, energy and climate adaptation, and we have years of experience in performing tasks related to energy and water systems, water resource management and waste water treatment.
Sensory analyses: An ALECTIA standard profile analysis considers samples of both fresh and aged products in order to produce a flavour stability analysis. We provide you with a thorough report commented by one of our brewing consultants.
Training and operation: Our training and operation services help ensure that your new plant is thoroughly tested, and your staff is trained and ready for full-scale production.
Technical service agreement: A technical service agreement with ALECTIA provides you with the reassurance of periodic assistance to safeguard high quality, prevent interrupted production and advise on the best next steps for your development.
Packaging and warehousing: ALECTIA can turn your warehouse into a smooth and efficient logistics facility tuned to support production and provide a consistently high service level to your customers. We help you plan the logistics flows and minimise cost of operation while promoting safety for your employees.
Miratorg’s factory in Kaliningrad produces hamburgers, nuggets, lasagna etc. to the Russian market. The production capacity per hour is 10 tonnes of finished products, which are frozen, packaged and sold in large batches to supermarkets and fastfood chains.
After a factory built in 2008 burned down in 2010, Miratorg started over again with the construction of a new food factory in Kaliningrad. ALECTIA was involved in the project from start to finish.
ALECTIA responsible for all process equipment
With a budget of approx. EUR 30 million, the Miratorg and ALECTIA project team has been in charge of the planning, procurement and installation of all process equipment for the new factory. This involved planning the layout of individual production lines and preparing requirement specifications for equipment suppliers. ALECTIA has also been responsible for tendering and tender evaluation and participated in the contract negotiations, followed by supervision of deliveries, installation and testing of the production equipment. At the end of 2012, the factory was ready for daily operation as one of the biggest food plants of its kind in Russia.
Miratorg selected ALECTIA to get facilities with quality standards which can be approved by the EU, with a view to future export possibilities.
“The client is happy with the new factory, which meets their requirements to quality, production capacity, etc. The factory is operating very well today,” said Senior Adviser Knud Rasmussen.
Additional projects for Miratorg
Since the completion of the project in Kaliningrad, ALECTIA has won more projects for Miratorg including the construction of a cattle slaughterhouse, a poultry slaughterhouse and two plants for packaged fresh meat.
Every day, the food company Hørkram transports tons of food to Danish restaurants, canteens, institutions and other catering establishments. The products range from bread, meat and fish to fruit, vegetables and frozen foods. Customers make contact daily to place new orders which must be ready for delivery the following day.
All Hørkram’s food products are stored and prepared for transportation at a 10,000 m2 warehouse in Kolt near Aarhus. The business is thriving, and the warehouse is becoming cramped for space for the many kinds of food. Hence, the company has decided to expand its cold storage facilities by no less than 7,000 m2 divided into 5,000 m2 cold storeroom, about 900 m2 refrigeration and approximately 1,100 m2 space for goods reception, offices and staff rooms etc.
In June, ALECTIA was invited to a meeting with Hørkram and offered an opportunity to present our capabilities and suggest possible solutions for the project. The client really took notice of our presentation, and following a series of negotiations Hørkram chose ALECTIA as client adviser. The final contract was signed on 8th October, and the construction process has just been kicked off.
An exciting new collaboration
As client adviser, ALECTIA is responsible for preparing tender documents and managing the main contract and the cooling contracts. In addition, we are responsible for all architectural and engineering services, project management and financial management. It is a major task of great importance to ALECTIA, not least because Hørkram is a brand new client with whom we hope to establish a long-lasting relationship. The tight schedule is also a challenge, as the cold storage unit is scheduled to go into operation by December 2014.
“This is an exciting and challenging task performed for an exacting client,” Market Manager at ALECTIA Frank Nyegaard said. “We are looking forward to carrying out the project and to cooperate with Hørkram – a new and interesting client.”
Hørkram wants to develop a greener profile, which is to be integrated into the project. This means, for instance, that ALECTIA will select the most energy-efficient solution for cooling the large cold store facility, construct a green roof, and install an associated solar cell system.
Despite a general lack of pigs in Denmark, Tican is expecting an increase in supply in the time to come. Preparing for this requires a 10.7 million EUR reconstruction project involving a new cooling tunnel and an enlargement of the existing equalisation chill rooms. ALECTIA is project manager on the project which extends over 1½ years and must respond to a variety of challenges in terms of regulatory requirements and environmental concerns.
“I am very pleased with the project progress so far,” ALECTIA’s project manager Johannes Back Pedersen said. “Tican has given ALECTIA the coordinating responsibility for the project, which we appreciate and take as a sign that we are regarded as one of the leading consultants in the food industry. It also helps us maintain ourlong-standing collaboration with Tican.”
The construction phase is about to begin following detailed preparations:
“We were contacted about a year ago and asked to come up with solutions as to how Tican can increase the capacity of the cooling tunnel and equalisation chill rooms to provide sufficient cooling when the number of slaughterings increases,” Johannes Back Pedersen said, adding: “They chose one of our three proposals, and together we went ahead with the project. In cooperation with DMRI, which is also part of the consultant team for the project, we then drew up a brief for submission to the board. In June, we reached an agreement with the board about a solution.”
In cooperation with Tican and DMRI, ALECTIA has planned the building process. ALECTIA has been responsible for the design of the cooling system plus all construction and authorities processing, while DMRI has designed the conveyor systems and specified the requirements for the cooling process.
Cooling process adapted to the future
In Tican’s future cooling tunnel, the warm pig carcasses will be cooled by means of cold air, removing most of the heat from the carcasses. An automatic conveyor system will transfer the carcasses to the equalisation chillers, where they will hang for 16-24 hours at about 5 degrees to reach a uniform temperature. Such efficient and controlled cooling helps to ensure the shelf life and quality of the meat.
The purpose of the expansion is to make room for more slaughterings per day while also optimising the cooling process to adapt the cooling speed and level to meet future standards.
Great savings potential
As main consultant, ALECTIA was responsible for coming up with suggestions for the form of expansion and the design that would get the most out of the large investment. Many parameters were taken into account, including cooling loss, increased profit, savings on wages and salaries, energy consumption, maintenance and cleaning costs, etc. – considerations which will make Tican able to save a considerable amount of money annually.
ALECTIA is also assisting Tican in getting the project approved by the Danish Environmental Protection Agency. A number of aspects must be considered, not least in relation to the environmental and safety risks associated with the use of ammonia refrigeration systems. For example, this issue can be solved by placing the cooling valves and cooling pipes of the cooling tunnel in a separate service area indoors rather than directly on the roof.
The construction process is expected to start in October 2013 and be completed in May 2014.
In 2013 and 2014, Arla Foods Ingredients is investing almost DKK 1 billion (EUR 134 million) in a major expansion of its factory Denmark Protein, including the construction of a new lactose plant. The plant will have an annual capacity of 85,000 tons of lactose (milk sugar) which will be used primarily as an ingredient in the production of infant formula.
A major project, the building complex and utility plant alone will cost more than DKK 200 million to construct. The new plant will take up 16,500m2, of which the process area accounts for approx. 10,000m2. The remaining area is for storage and supply systems.
Strong emphasis on cooperation
For this project, Arla Foods Ingredients has put a new cooperation model into use, whereby contractors are selected early in the process and will be involved in the planning and design process together with the client, the suppliers and the consultants. That way, everyone may offer qualified professional input already in the conceptual phase.
According to ALECTIA’s business manager Rolf Pedersen, the cooperation between contractors, suppliers and consultants is an important reason why the project can be implemented in such a short time. The cooperation means that all parties will meet weekly to review the progress and discuss solutions, both in the design phase and during the implementation of buildings and installations.
“The project time is very short, which is possible because there has been a major focus on collaboration from the outset,” Rolf Pedersen said. “The contractors were chosen based on their previous cooperation experience on construction projects. It has been a requirement that all participants have a spirit of cooperation, so that we can take a solution-oriented approach to the project.”
Growing demand for lactose
The new plant will be able to produce 85,000 tons of lactose annually. In the process, lactose is extracted from whey by filtration, evaporation and crystallisation. The final product is mainly used in products for infants and as an ingredient in the food industry. In the future, Arla Foods Ingredients will process a higher proportion of whey lactose into ingredients, while today a significant part is sold as liquid animal feed.
The increasing global demand for lactose for infant formula is the underlying reason for the construction of a new lactose plant. Its design considers customer requirements to the lactose quality of the future to make sure that the plant can continue to provide lactose products of the highest quality to the global food industry.
According to plan, the new plant will be put into operation in October 2014.
ALECTIA performs simulations of production plants to ensure food companies a cost-effective and future-proof design. By testing different scenarios we can ensure the right balance between performance, flexibility and investment. Simulation is thus a valuable tool for designing new factories as well as optimising existing production plans, providing security about the results of the investment.
New plant for a large international client
ALECTIA has helped a large international client design a new factory using simulation. ALECTIA was responsible for developing business plans, optimising the client’s production structure and developing a basic design including process plants, utilities, distribution centre, automated high bay warehouse, site layout, architecture, staffing plans, operating records and building accounts.
We used simulation of the new production plant as part of the basic design project, which involved a number of improvements in relation to the existing factory. By means of a 3D dynamic simulation model, the assumptions on which the design was based were visually validated, allowing the client to be confident that the new plant would be able to handle the production.
Simulation of new production plants in the food industry gives visual confirmation that the plans can be realised. Simulation shows e.g. the consequences of potential production breakdowns and the impact of variations in product mix and volumes. Thus we ensure our customers a strong and clear connection between design and operation.
Since a new production facility is always designed based on expectations for the future, for new and optimised processes, and for improved efficiency, it is extremely important to ensure that the plant will have a robust design which is not oversized. ALECTIA’s simulation model helps to ensure that the consequences of design choices and variations in the production will be accounted for in a tangible way.
Simulation offers several advantages
Simulation of new or existing production plants give a valuable basis for optimising various areas. Simulation make it possible to:
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