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CGE - Modular Plant Concepts

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HQLCP

The principle objective of any ceramic plant must be to produce product at the Highest Quality, Lowest Cost per Piece (HQLCP). In pursuit of HQLCP the main cost control factors must be applied to all of the constituent parts of the production process. These cost control include financial cost; labour; materials; energy (fuel and electricity); associated overheads and yield. If a commercial advantage can be obtained in any of the above cost control factors, it will result upon the Company's profitabilityighest Quality - Lowest Cost per Piece.

CGE offer the benefits of :-* Plant design based on highest quality lowest overall cost per piece. * Large scale production plant assembled as a series of smaller production units over a period of time allowing production to grow with the market demand. * CGE design, manufacture and install all the key elements of the plant. * Logical and scientific approach taken to eliminate any cost efficiency effecting the overall cost per piece. .

Case study : Modular Sanitaryware Plant

Although primarily known for its experience in the design of kilns, dryers and furnaces, CGE has developed an expertise in the design of complete sanitaryware facilities. This culminated in the installation of a complete turnkey facility for HJ Ceramics in Brighouse, established as the manufacturing arm of Heritage Bathrooms. One of the keys to the success of this latest project has been the use of the modular concept, which CGE had previously employed so successfully elsewhere. The Brighouse installation was to benefit significantly from this experience. The principle underlying the modular concept is that large scale production plant is assembled as a series of smaller production units over a period of time. This allows considerable elements of capital cost to be defrayed and allows revenue generated by the first units to support the construction of additional units. In the case of HJ Ceramics, there are two phases - the capital cost of phase two is approximately two thirds of that of phase one. This two-phase method has several advantages: - * By reducing the initial capital cost necessary for production, the overall risk element of the project was significantly reduced. * By obtaining production out of phase one, revenue becomes available to ease the financing of phase two. * The smaller phase one unit was able to be in production more rapidly than the larger unit. * Consequently not only were financial returns more rapid, but by having the production underway, it was possible to benefit in the design of phase two, with the experience derived from the results and operating systems of phase one.

Delays in obtaining access to the 60,000 square ft unit meant that the original 18-week plan had to be compressed into a mere 12 weeks in order to meet targeted production schedules. This tight schedule was achieved and progress from an empty factory to first casting was indeed within this 12 week period. During this time it was necessary to supply all the gas and electrical services as well as modifying the unit's civil work to accept the construction of the mould shop, effluent treatment plant, return slip, compressed air house, drainage, and other items. This work was all overseen by CGE who were appointed as the main contractor as well as plant designer.

Performance Cras enim. Vestibulum ante ipsum primis in faucibus orci luctus et ultrices posuere cubilia Curae; Ut eu augue. Integer risus wisi, semper eu, congue quis, lobortis ut, massa. Vestibulum auctor vestibulum lectus. Vivamus neque. Cras lobortis. Aenean ut turpis eu libero volutpat euismod. Donec eget lectus vitae ligula ornare tempor. Vivamus scelerisque lorem a elit. Sed id mauris.

Mould Condition Cras enim. Vestibulum ante ipsum primis in faucibus orci luctus et ultrices posuere cubilia Curae; Ut eu augue. Integer risus wisi, semper eu, congue quis, lobortis ut, massa. Vestibulum auctor vestibulum lectus. Vivamus neque. Cras lobortis. Aenean ut turpis eu libero volutpat euismod. Donec eget lectus vitae ligula ornare tempor. Vivamus scelerisque lorem a elit. Sed id mauris.

Transport and drying of ware Cras enim. Vestibulum ante ipsum primis in faucibus orci luctus et ultrices posuere cubilia Curae; Ut eu augue. Integer risus wisi, semper eu, congue quis, lobortis ut, massa. Vestibulum auctor vestibulum lectus. Vivamus neque. Cras lobortis. Aenean ut turpis eu libero volutpat euismod. Donec eget lectus vitae ligula ornare tempor. Vivamus scelerisque lorem a elit. Sed id mauris.

Firing Cras enim. Vestibulum ante ipsum primis in faucibus orci luctus et ultrices posuere cubilia Curae; Ut eu augue. Integer risus wisi, semper eu, congue quis, lobortis ut, massa. Vestibulum auctor vestibulum lectus. Vivamus neque. Cras lobortis. Aenean ut turpis eu libero volutpat euismod. Donec eget lectus vitae ligula ornare tempor. Vivamus scelerisque lorem a elit. Sed id mauris.

Control Strategy Cras enim. Vestibulum ante ipsum primis in faucibus orci luctus et ultrices posuere cubilia Curae; Ut eu augue. Integer risus wisi, semper eu, congue quis, lobortis ut, massa. Vestibulum auctor vestibulum lectus. Vivamus neque. Cras lobortis. Aenean ut turpis eu libero volutpat euismod. Donec eget lectus vitae ligula ornare tempor. Vivamus scelerisque lorem a elit. Sed id mauris.

Commercial Success CCGE's Modular Plant Concept is a turnkey project in the true sense of the word, as CGE has designed, manufactured and installed all the key items in the plant, including all kilns, dryers, heating and ventilation systems, slip preparation and casting systems.

CGE places a great deal of emphasis on the success of their customers' business concentrating on their requirements from a production, quality and commercial standpoint. In doing so, CGE can design a plant to grow with the customers' market. Throughout the design stages CGE based its principles on 'Highest Quality Lowest Cost per Piece' (HQLCP) , with the most important and ultimate aim of achieving the highest possible yield.

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