FAST NEW PRODUCTION LINE GIVES KNAUF DRYWALL AN EDGE
Knauf Drywall has commissioned one of Europe’s fastest plasterboard production lines as part of a major capacity upgrade at its Immingham factory.
The expansion doubles potential output of the Humberside factory. Together with the output of its other UK factory, at Sittingbourne, Kent, this increase enables Knauf Drywall to ensure excellent supply, product quality and customer service in a growing market. At the same time, a new fleet of delivery vehicles will increase Knauf Drywall’s presence on the road.
Production at Immingham has resumed on schedule after a brief shutdown to commission the new production facility, which includes additional warehouse space. The expansion was designed by Knauf Engineering and project managed by the UK Production Director, Axel Hoell.
Knauf Drywall Managing Director Barry Topple said careful production planning ahead of the commissioning period ensured no interruption in deliveries to customers and meant that Knauf Drywall has maintained its industry leading service standards.
"The Knauf group has already invested more than £100 million in UK plasterboard and plaster production since entering this market in 1988. Market demand has outstripped manufacturers’ ability to maintain supply from UK manufacturing plants. This investment puts Knauf in the strongest supply position, and further demonstrates our commitment to this market and its customers."
Constructed over 11 months by local contractor Clark Construction, the building works involved 700 tons of steel, 8,000 tons of concrete, 50km of steel reinforcing bar, 2,500 tons of tarmac, and 36km of piles. There is more than 6,000m2 of external cladding.
Paul Snowden, Knauf Drywall’s Immingham Plant Manager, says the first new equipment arrived in July 2005. "A new calcination plant was built alongside existing machinery. The new 500 ton dryer was assembled in the extension and winched 63 metres into position while the plant was shut down. Some existing equipment had to be moved to new positions related to the new dryer – this was achieved by removing roof sections and lifting the items with 300 ton cranes."
He says the new dryer is designed to give greater flexibility in the drying process, while new conveyors will handle boards more gently. "By drawing on best practice developed over many years in the Knauf group, we are able to achieve highest product quality at the increased speeds." A new fleet of LPG trucks in the warehouse will ensure that products are dispatched to customers in the best possible condition.