Are specialist, ISO 9001 certified,  manufacturing engineers who plan, design and implement end-to-end engineering solutions for the specialised consumer goods manufacturing sector. By understanding our clients’ needs we design and build manufacturing plants that not only meet current demands but also ensures the facility accounts for growth and future capacity needs.

While our methodology is founded on sound engineering principles, our solutions are tailored to optimise business output through efficacy in all aspects of the planning, design, implementation and construction. Starting with a comprehensive understanding of the manufacturing operation, Astratek Manufacturing Engineers designs facilities that optimise plant operations.

We combine our expertise in modern consumer packaged goods (CPG) and fast moving consumer goods (FMCG) manufacturing operations with a vigorous analysis of process requirements to transform market demand into facilities that meet manufacturing requirements.

As members of EHDG (European Hygienic Engineering & Design Group),  our unparalleled understanding of hygienic engineering and compliance results in engineered-in compliance and product safety reducing the needs for manual protocols and procedures, ultimately delivering facilities which are more effective and resilient.

PROCESS ENGINEERING

ASTRATEK employs operational modelling to determine the most effective production processes and its required capacity. We understand a facility is only as good as its equipment. Our rigorous approach therefore relies on extensive knowledge of the OEM market to ensure we use only the most suitable technology from the most reliable suppliers. Our experience allows us to create designs and solutions blending good technology with commercial decisions. This ultimately determines our process selection.

1. Process design (Flow Sheets, P&IDs)
2. Capacity Studies
3. Equipment selection and specification
4. Specialist equipment selection
5. Equipment layouts

FACILITIES DESIGN

Proper facilities design supporting good flow is the cornerstone of efficient plant operations. In addition, modern manufacturing plants require a raft of support functions to be effectively integrated into the facility. Astratek Manufacturing Engineers understands how modern manufacturing plants work and are adept at understanding how materials and people flow through the facility along with the requirements of maintainability, cleanability and compliance. These, often conflicting, requirements are effectively integrated through time honed methods, multi-disciplinary design teams and a set of proprietary tools. Continuity is ensured through a comprehensive ISO 9001 compliant project delivery system.

1. Materials analysis using proprietary ASTRATEK tool
2. Accommodation planning – Including production halls and ancillary requirements
3. Material flows and shop floor logistics
4. People flows
5. Design optimised for ease of maintenance and cleaning
6. Civil and Structural engineering
7. Hygienic design
8. Waste and effluent handling
9. Building Services

ENGINEERED FACILITIES

Manufacturing facilities and plants require as many as 38 different services critical to operational success. A plant with underperforming services and utilities can quickly come to a standstill. ASTRATEK therefore insists on fully engineered utilities to ensure reliability and performance. Our designers plan specifically for reliable services and utilities.

Cutting-edge engineering tools and methodologies are employed to fully analyse all the utilities required. This is done to ensure on-spec performance from start-up, plant longevity as well as to support the ease of maintenance to optimise equipment service life.

• Process specific requirements (e.g., glucose, glycerine etc.)
• Steam, Compressed air, fuels, vacuum
• Hot, cold & chilled water
• Potable water
• Process heating & cooling
• Refrigeration
• Electrical and standby power
• Solar PV
• Access control, Time and attendance, CCTV
• MAP  Gasses

Astratek’s approach to construction management is founded on the doctrine of direct contracting. This aims to contract directly with the specialist service providers improving site control and avoiding “margin on margin” spend. Robust site management and control as well as full time management of site safety and compliance requirements by construction health and safety specialists is achieved by having ASTRATEK staff on-site throughout the project lifespan.

ASTRATEK’s flexible approach to construction management allows for a range of commercial arrangements from full turnkey (EPC) to design and managed construction projects (EPCM).

By choosing ASTRATEK you benefit from;

• Dedicated on-site management,
• Dedicated site health and safety management by specialists,
• Direct project contracting (reduced risk),
• Project financial control,
• Estimate Cost to Completion (ECC) – Proprietary ASTRATEK budgeting tool

TBC