Manufacturers of polystyrene trays.
Britton Electric’s Mandate
During the manufacturing process of polystyrene trays, plastic pellets are extruded with expansion gas, with the resulting product stored in rolls. These rolls are then formed in to polystyrene food trays.
In September 2004, a fire ravaged the Dyne-A-Pak plant and approximately 40% of the facility was destroyed including production and warehouse areas.
As part of the reconstruction of this 180,000 square foot facility, Britton Electric was given the mandate to repair and re-install or replace all required electrical systems as well as rebuild and refurbish all the manufacturing equipment.
The Scope of Work
Following the fire, a large portion of the Dyne-A-Pak plant was taken down to the ground and a new structure was erected. Britton Electric was an active member in the overall effort, participated in the design process and supported the engineering projects from concept through to completion. Britton Electric was able to provide essential information because in the late 1980’s, when Dyne-APak changed the plant’s extrusion process, the Company was the contractor for the entire electrical installation.
During the redesign and rebuilding of the plant, Britton Electric was responsible for the installation of all the electrical wiring, plus the cleaning and verification of the interior 4,000 KVA substation that had sustained extensive water infiltration and damage.
Additionally, Britton Electric replaced the control panels on all the equipment that included a stand-alone grinder with explosion-detection equipment and a stand-alone shredder, underwater pelletizers, reclaim extruders, polystyrene flake conveying system, virgin resin conveying system, dust collection system, an LEL (Lower Explosive Limit) 24 point detection system and 2 toxicity detection systems.
Britton Electric cleaned and rebuilt the thermo-formers and the tandem extruders that were contaminated by smoke and water, a process that included the removal and cleaning of all the components of the control units and panels.
- New construction
- Power distribution
- Transformers and switchgear
- Interior and exterior lighting
- Fire alarm systems
- Lighting control
- Electrical heating
- Preventative maintenance
Britton’s Specialized Expertise
- Industrial equipment installation
- Plant set-up
- Instrumentation and control
- Robot controlled systems
- Instrumentation and control
- Repair, refurbish and rebuild electrical equipment
- Uninterruptible Power Supply (UPS) systems
- Emergency generating systems
- Motor control
- Power factor correction
Dyne-A-Pak required extensive electrical work to be completed as part of the overall rebuilding of the manufacturing facilities. During this time Britton Electric worked very closely with the owners, general contractor and the engineers to ensure that every part of the mandate was met according to a strict schedule. Insurance adjusters strictly monitored all aspects of the work; estimates were required for each element, detailed billing was needed and all costs were rigorously examined. Britton Electric cooperated with the insurance company and carefully managed the necessary administrative details.
Meeting the deadline to restore the manufacturing facility was critical to the survival of Dyne-A-Pak. Polystyrene is a low-cost commodity product and due to the nature of industry, Dyne-A-Pak could not be out of the marketplace for any extended period of time. They had to be back in production within 6 months and if the project had taken longer, the company would have been out of business.
Notwithstanding the enormous pressure under which the client and the entire team had to work, within 5 months Dyne-A-Pak was operating at 50% capacity. Remarkably, a few months later the company was able to operate at full capacity. This allowed Dyne-A-Pak to maintain its customer base and remain a successful company in its sector.
To complete the project it took 1 project manager, 1 engineer, 4 technicians, and on average, 12 electricians. At times, there were as many as 20 electricians on site.
What Britton’s people brought to the table
- Deliver excellence under pressure
- Work closely with the client, general contractor and engineers
- Cooperated with and managed the detailed administrative procedures required by an insurance company
- Perform as an integral part of a large and extensive project
- Meet strict deadlines in a critical project
- Provide the expertise required for a wide variety of jobs