Malone Group delivered the full mechanical and electrical design for the integration of a new steam boiler and ancillary equipment into a food manufacturing facility. The scope covered mechanical design including steam distribution, condensate recovery, water and hot water systems, compressed air and a natural gas skid upgrade with gas detection. Electrical works included power distribution, fire alarm integration, access control, lighting and BMS integration with the existing system.
A key challenge was ensuring sufficient high-pressure hot water availability during equipment cleaning. Temperature drops occurred during equipment cleaning due to short 15–20 minute peaks in hot water demand that exceeded the capacity of the existing heat exchanger. Malone Group conducted a detailed analysis of the facility’s hot water usage and engineered a solution incorporating a 5,000L hot water storage tank maintained at 65˚C to absorb peak demand while remaining integrated with the heat exchanger.
