Project Description:
Kraft Heinz is a global leader in the food industry, known for delivering high-quality food and beverages through its iconic brands worldwide. Born from the merger of Kraft and Heinz in 2015, the company has roots dating back to 1777.
Kerfoot was engaged to design, supply, and install dual input 2500A main switchboards at their facility, with the goal of enhancing power distribution while maintaining operational continuity throughout the upgrade. The project involved extensive investigations to assess the viability of integrating existing transformers, as well as the removal and replacement of outdated switchboards. Structural modifications were required to accommodate the new equipment.
The project included the replacement of two power factor correction units, upgrading of the main earthing systems, and lighting, with backup power provisions using generators to ensure uninterrupted operations.
The work was completed within a tight 3-day timeframe, with careful planning to minimise downtime and ensure compliance with safety and regulatory standards. Notable challenges included managing space constraints and coordinating with multiple stakeholders, including Kraft Heinz and Endeavour Energy. The installation adhered to industry standards and was designed to allow for future scalability.
Specific items within the scope of this project were:
- Investigation and Assessment: Evaluated the feasibility of using existing Endeavour Energy transformers, including load assessments and condition reporting, and coordinated with Endeavour Energy engineers for integration with new switchboards.
- New main switchboard design to suit the clients current and future needs
- Switchboard Removal and Replacement: Removed the old switchboard within a tight timeframe, ensuring minimal operational disruption with careful planning.
- Structural Modifications to the room: Designed and installed custom supports for the new switchboards, ensuring compliance with safety and operational requirements due to space constraints in the existing switch room.
- New Main Switchboard Installation: Installed dual input 2500A main switchboards in a limited space, with future upgrade capacity and compliance with electrical standards.
- Power Factor Correction Upgrade and replacements (2 of): Optimised the power factor correction system to improve efficiency, reduce costs, and meet power quality standards.
- Lighting: Installed new lighting in the switch room to enhance visibility and meet safety and maintenance compliance.
- Backup Power Provision: Used generators to maintain an uninterrupted power supply during critical changeovers to keep the site operational.
- Engineering: Designed the system to minimise cable joins, ensuring efficient integration with the new switchboards.
- Earthing: Upgraded the earthing system to meet current compliance standards.
Project Accolade:
- Delivered a complex live-site switchboard upgrade within a critical 3-day shutdown window, ensuring zero impact to ongoing manufacturing operations through meticulous planning and staged execution.
- Successfully designed and installed dual input 2500A main switchboards, enhancing network reliability, redundancy, and future scalability for a major global food production facility.
- Maintained uninterrupted site operations through strategic generator integration, enabling seamless power continuity during critical changeover periods.
- Engineered a bespoke solution within a constrained switch room environment, including structural modifications and custom supports to safely accommodate new infrastructure.
- Delivered a future-ready electrical infrastructure solution, incorporating design considerations for expansion, reduced cable joins, and long-term operational efficiency.
