Case Studies

Totally Natural Solutions, a company specializing in hop extract production, engaged our multidisciplinary team to design their hop extract processing plant. The main objective of the project was to develop a plant that would produce high-quality hop extracts tailored to meet their customers’ specific needs.

We began the project by gaining a thorough understanding of Totally Natural Solutions’ hop extract production process, including inputs, outputs, and process requirements. Based on this understanding, we developed the front-end engineering design (FEED) and detailed design for the processing plant, which included process flow diagrams, equipment specifications, and control system design.

Throughout the project, our team worked closely with Totally Natural Solutions to ensure that the design met their requirements and aligned with their business goals. We also supported the client in selecting and procuring the necessary equipment and materials, and supported through the installation.

IDEA was approached by a client who was seeking support in designing their whisky distillery in Norway. The project covered all key areas of distillery design, including malt intake, milling, mashing, fermentation, distillation, and utilities.

Our team took a holistic approach to the project, considering key factors of whisky distillery design such as sustainability, energy efficiency, safety, and compliance with regulations. We conducted a thorough review of the client’s needs and goals to develop a detailed understanding of their requirements across all the processes including malt intake, milling, mashing, fermentation and distillation.

IDEA was approached by a client who needed support with a concept study for a large green field project valued at several million pounds. The project consisted of bulk storage with multiple vats, utilities, cask fill and drain, and robotics.

Our team worked closely with the client to develop a comprehensive understanding of their requirements and objectives. We conducted a thorough review and developed a plan for the new green field project.

The project’s bulk storage included multiple vats, which we designed to meet the client’s requirements for size, capacity, and flow rate. We also designed a system for utilities, including water, compressed air, to support the operations.

In addition, we prepared a preliminary design for a cask fill and drain system that utilized robotic technology to maximize efficiency and minimize labor costs. This system also enabled consistent filling and emptying of the casks, resulting in higher quality spirits.

Throughout the project, we ensured that the design of the distillery aligned with relevant regulations and industry standards. We also incorporated sustainable design elements.

The outcome of the project was a comprehensive concept study that provided the client with a clear vision for their green field project. Our team was able to deliver a design that met the client’s needs while also incorporating innovative and sustainable solutions.

IDEA have been supporting clients by conducting piping stress analysis for stress critical lines including those under high pressure or high temperature, to ensure they were capable of withstanding the operational loads.

Projects have involved conducting a detailed review of the piping systems, including their geometry, materials, and operating conditions. We then utilized specialized software to model the piping systems and simulate their performance under various loads.

We conduct comprehensive stress analysis of the piping systems to identify any potential stress concentrations, excessive deformation, or other potential issues. Based on the results of our analysis, we provided recommendations for modifications or repairs to ensure the safe and efficient operation of the piping systems.

Throughout the project, we work closely with the client to ensure that our analysis and recommendations aligned with their objectives and requirements. We also ensured that our work complied with relevant industry standards and regulatory requirements.

The outcome of the project was a detailed report that provided the client with a clear understanding of the performance of their stress critical piping systems. Our stress analysis enabled the client to identify potential issues and implement solutions to mitigate any risks. We take pride in providing our clients with high-quality engineering solutions that ensure safe and efficient operation of their systems.

We provide expertise specialising in process safety studies including HAZOP, HAZID, LOPA, DSEAR and Hazardous Area Classification.

The project required expanding the current capacity of bulk storage with the addition of multiple vats, valve blocks, pumps, heat exchanger, filters etc.

Our team worked closely with the client to develop a comprehensive understanding of their requirements and objectives. Throughout the project, we ensured that the design aligned with relevant regulations and also seamlessly integrated with the existing plant infrastructure (mechanically, electrically and control systems).

Some of the key deliverables as part of the project included:

As part of their site expansion projects and management of change requirements IDEA were engaged by Brewdog to assist with developing site wide Hazard Identification (HAZID) studies, to ensure that as the site grows the hazards of adjacent operations, traffic movements and process hazards are all well understood.

A full site HAZID ensures that all operating and logistical factors can be considered together, and provides the client’s management a snapshot of all the major risks present on the site.

As part of the project to design the move of the clients distillery from one location on site to another, as well as expansion of the distillery with new equipment, IDEA also took on the role of independent risk assessors. With multiple in house hazard study leaders we were able to carry out this role completely independent of design, to ensure the design elements could be objectively challenged.

The project process included HAZOP study, LOPA study for high severity events and DSEAR and Hazardous Area Classification updates for the new site operations.

IDEAs process safety team also helped to save the client significant CapEx and OpEx on their distillery services, by suggesting improvements to ventilation, without the need for forced extraction systems.

We drew on our vast experience in the distilling sector to show the client how natural buoyant Distventilation could be made use of to provide effective stillhouse ventilation.