Client Key Facts

• Client Name: Alcohols Ltd
• Industry: Chemical & Distilled Spirits
• Project Site: Rugby, UK
• Objective: Design and construct a state of the art manufacturing facility to enhance production and distribution capabilities whilst ensuring manufacturing sustainability.

Alcohols Ltd Background

Alcohols Ltd, a leading manufacturer in the chemical and distilled spirits manufacturing industry, specifically focus on the production and distribution of alcohols and industrial chemical products. These industries encompasses a broad range of activities, including the manufacturing of industrial alcohols, spirits, solvents, and other related compounds used across various sectors such as pharmaceuticals, cosmetics, food and beverage, and industrial applications.

Alcohols Ltd emphasises quality control and compliance within a highly regulated industry. This includes adherence to production, environmental and safety standards, ensuring their products are safe and effective for their intended uses.

Based upon on significant process engineering and EPCM experience, Alcohols Ltd chose Ai Process to design and project manage the construction of their new manufacturing site in Rugby, UK.

Ai Process Scope of Works

Operating as Principal Contractor, Ai Process undertook the comprehensive design and project management of the new manufacturing site, ensuring the facility met Alcohols Ltd’s high standards.

The site development was divided into two individual manufacturing facilities including solvents and gin distillery.

The scope of works included:

• Front End Engineering Design Study (FEED Study)
• Risk assessment studies including HAZOP, DSEAR, PHA and SIL
• Energy usage assessment
• Bulk solvent tank farm design and construction
• Solvent manufacturing facility design and construction
• Bulk distillery tank farm design and construction
• Distillery manufacturing facility design and construction
• Supply of supporting process services and infrastructure
• Plant Commissioning and Handover

Outcome and Benefits

The new manufacturing site in Rugby stands as a testament to the successful collaboration between Ai Process and Alcohols Ltd. Key benefits realised from the project include:

Production Optimisation

Ai Process significantly enhanced production efficiency at Alcohols Ltd’s new facility by implementing process automation technologies and streamlined manufacturing workflows to optimise throughput and reliability.

Production Cost Reduction

Through the adoption of lean manufacturing principles, optimised process flow and cost-effective technologies, Ai Process helped Alcohols Ltd achieve substantial production cost savings. Optimised raw material usage, reduced waste, and improved maintenance protocols contributed to lowering production costs, enhancing the overall financial efficiency of the manufacturing facility.

Regulatory Compliance

Ensuring compliance with stringent industry regulations was a critical aspect of the project. Ai Process designed the facility to meet regulatory industry standards, incorporating advanced safety systems and comprehensive documentation processes.

New Formulation Capabilities

The facility was equipped with versatile production lines capable of handling new product formulations. Ai Process designed flexible systems that could easily adapt to changing formulation requirements, enabling Alcohols Ltd to innovate and rapidly bring new products to market. This adaptability ensured that Alcohols Ltd could meet evolving market demands and maintain a competitive edge.

Conclusion

Ai Process’ experience in process engineering and EPCM was instrumental in the successful development of Alcohols Ltd’s new manufacturing facility. By addressing critical improvement areas such as production efficiency, process optimisation, and environmental sustainability, Ai Process delivered a state-of-the-art facility that positions Alcohols Ltd for continued growth and success in the chemical and distilled spirits manufacturing industry.

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