The ‘Black Swan Event’ Factory Refurbishment Project
The four-month project, dubbed the ‘Black Swan Event,’ overhauled and modernised BEP’s electroplating operations and enhanced its sustainability credentials.
The phased programme, notable for its scale and complexity, involved the removal of large electroplating tanks, with capacities ranging from 4,500 to 15,000 litres, along with all ancillary equipment, including buzz bars, local exhaust ventilation (LEVs), cooling coils, and heating elements.
Sustainability and Environmental Considerations in the Factory Refurbishment
Over 31,500 litres of chemical solutions, including sulphuric and caustic substances classified as hazardous waste, were extracted and safely disposed of, adhering to strict environmental regulations. The company retained the chrome tank solutions for reuse, further aligning with its sustainability objectives.
Subsequent phases involved extensive renovation to the pit floor and walls, which was then relined with a robust, chemical-resistant coating. The project concluded with the installation of four newly designed tanks, establishing a foundation for decades of enhanced productivity and reduced maintenance.
Precision Engineering and Long-Term Operations Post-Factory Refurbishment
BEP electroplates components for various industries, including nuclear, packaging, manufacturing, defence, and aerospace. As such, it specialises in precision turning and cylindrical grinding of a wide range of industrial components, from pump shafts to chill rolls, handling weights from a few kilos to 20 tonnes.
Innovative approaches to pit factory refurbishment continue to be a cornerstone of BEP’s legacy. The company’s last refit was almost thirty years ago. This latest initiative underscores BEP’s ongoing commitment to sustainability, operational efficiency, and safety, ensuring that the newly modernised facility will not require another factory refurbishment for several decades.
Collaboration and Project Success in Factory Refurbishment
BEP collaborated with key contractors, including CSG, a prominent UK waste management firm, for cleaning operations; Arc Fabrications Ltd., for tank fabrication and installation; and Coral Eastern, for concrete and lining services, to ensure the success of this ambitious project. This extensive factory refurbishment modernised BEP’s facilities while ensuring compliance with stringent environmental regulations and enhancing long-term operational reliability.
Managing Director’s Insight on the Factory Refurbishment
Andrew McCluskey, Managing Director at BEP Surface Technologies, commented, “The new infrastructure streamlines processes, minimising downtime and enhancing productivity. This project is what I refer to as the ‘Black Swan Event,’ with an anticipated operational lifespan spanning several decades. We undertook this factory refurbishment to utilise our expertise and ensure every detail aligned with our operational needs. Some might argue that third parties are better suited to complete such projects, but we know our factory intimately, and dedicating all our resources to this initiative made perfect sense. By investing in durable materials and thoughtful design, we have secured a facility that will endure long beyond my tenure at the company. This refurbishment showcases BEP’s commitment to innovation and sustainability, enhancing efficiency and reinforcing our environmental responsibility.”
A Collaborative Effort for Long-Term Success Post-Factory Refurbishment
Lewis Brierley, 26, who led the project and is part of BEP's expert chemical team, stated, "This project required a balance of technical precision and sustainability. By collaborating with industry specialists and utilising advanced materials, we have extended the operational life of critical infrastructure by decades. This refurbishment is not merely an upgrade but a future-proof solution for both environmental and economic efficiency."
He further explained that he drew from the experience of BEP’s Founder and Director, Steve Howard, who had commissioned the first pit over 40 years ago.
Lessons Learned from Previous Factory Refurbishment Projects
“Working with Steve, the original architect of the pit, has been invaluable. His decision to exclude limestone from the concrete over forty years ago demonstrated remarkable foresight and has contributed to the pit's longevity. Drawing on his extensive knowledge during this refurbishment has been a tremendous learning experience, and we are implementing modern solutions to ensure the facility serves us well,” added Lewis.
Critical Infrastructure Enhancements Post-Factory Refurbishment
A critical aspect of the refurbishment was restoring and reinforcing the concrete pit to restore its structural integrity. BEP opted for a high-performance fibreglass-reinforced epoxy resin lining to enhance durability and chemical resistance, which was rigorously tested to withstand harsh conditions. New titanium-lined tanks with upgraded three-millimetre liners replaced the previous one-millimetre versions, improving durability and reducing maintenance requirements.
Final Stages of the Factory Refurbishment
The project concluded with the reinstallation of state-of-the-art ancillary components to improve operational efficiency and safety, including a redesigned operator flooring system that provides 360-degree access.
Sustainability and Long-Term Benefits Post-Factory Refurbishment
This factory refurbishment significantly enhances sustainability by reducing environmental impact by retaining and storing chrome solutions instead of disposal. The revamped facility now features improved flooring and equipment accessibility, ensuring a safer working environment for operators. Advanced materials, such as the Belzona 4341, are used. This durable, two-part epoxy barrier coating is optimised to resist hot inorganic acids such as sulphuric and hydrochloric acid up to 90°C (194°F).
