The Unilever Gloucester factory is one of the largest ice cream producers in the UK. It manufacturer’s a range of products under the iconic Wall’s brand.
The primary refrigeration system; which serves low temperature freezing process loads across the facility; is large, complex and operates with ammonia as its refrigerant. STS has worked with the Unilever Gloucester engineering team for many years, providing a range of support, including: regulatory compliance, specialist consultancy and bespoke training.
The regulatory compliance support has consisted of the preparation of Written Schemes of Examination and their on-going associated inspections, under the requirements of the Pressure Systems Safety Regulations (PSSR) 2000, and the preparation of a site Ammonia Hazard Assessment, under the requirements of the Dangerous Substances & Explosive Atmosphere Regulations (DSEAR) 2002 and the Management of Health & Safety at Work Regulations (MHSWR) 1999.
The specialist consultancy has included a range of functions from technical specification preparation, to design & installation documentation review, to HAZOP studies.
The bespoke training involved the review and validation of Unilever staff Service Engineer competencies, as they related to their role in operating & maintaining the ammonia refrigeration system. The exercise had several elements to it including:
Following this exercise STS graded the Service Engineer and suggested, where appropriate, additional training that would benefit the individual.
At the end of the exercise the Unilever Gloucester management and the individual Service Engineers had a clearer understanding of where they stood in terms of competence and just as importantly what could be done additionally to improve their capability.