EVERYONE HAS PROCESSES 
 
From individuals cooking at home, to oil refineries, all have a common factor: they change the condition or state of a product. 
 
The changes may vary; chemical composition, shape, temperature, solid to liquid to gas or back, removing unwanted product, introducing new product, the list is not exhaustive. 
 
Many processes involve manual operations – that is, people are needed to make them - and in some cases this is appropriate. 
 
 
 
 

PROCESS PLANT SECTOR Challenges / Opportunities  

Some of these conditions can be extremely challenging and potentially hazardous. The nature of many products manufactured or handled in a process plant can have a risk of explosion, fire, toxic releases and potential environmental damage, and in many cases extremes of temperature pose a hazard to personnel. 
 
Automated Process Plants are designed to make production safer, reliable and more efficient whilst providing you with measurements and information about what is happening on the plant without the need for an operator to be constantly and physically present at every stage. They can involve handling raw materials, heating and cooling, pumping, mixing, pressurising and all under known controlled and repeatable conditions. 

AUTOMATED PROCESS PLANTS  

Automation is a way of ensuring that a process remains consistent and reliable. Often this requires a precision that can mean the difference between a stable product and a potential hazard, and this requires detailed assessment of the risks. Automation not only provides a “hands off” opportunity to control a plant but also the means to measure and record the conditions and parameters so that the process can respond to changes in status and in time without intervention. Humans often form part of this operation, and an automated process plant may include points where an Operator must make a decision, manual change or a physical operation in order to complete the sequence. 
 
The further advantage of automated plant is that the information can be used retrospectively to analyse batches, provide a quality assurance to the end users and to forensically identify errors, inconsistencies or plant failures, and often can be done in a historical pictorial form that the operators and plant managers can be familiar with from use of the live system. It is also common, although we always advocate a solid security approach, that the plant data can be viewed remotely so those not based at the production facility, or duty process engineers, can anticipate problems before they become reality, without having to spend time getting to site first. 

MATL IN THE PROCESS PLANT SECTOR  

Our methodical approach to engineering, hazard and risk assessment, functional and operational safety ensures we highlight any potential issues and provide suitable engineering solutions to reduce the potential of them from happening. 
 
Process plants are frequently different and we have the flexibility to rapidly understand the requirements and adapt to changes, whilst still maintaining control over the process plant project. 
 
As many process plants have the potential for explosion, fire and pollution, our engineering team will work to ensure the risks are minimised without compromising operability. 

MANY YEARS OF EXPERIENCE  

MAT Ltd have many years of experience of understanding new and modifying processes, how product changes within a plant, and how to deal with hazardous conditions and risk management in the design. 
 
Complete raw material batching to finished product, processing of waste material to generate electrical or heat energy, or transferring challenging fluids and gases. We have experience in developing and design of complex systems of product handling, chemical processing and hazardous process management. 
CLIENTS INCLUDE 
 
We have worked with clients across different markets and products, including energy from waste through gasification, resin manufacture, 
pharmaceutical, paint, toothpaste and cement. 
 
 
ITI Energy 
PPG 
Kew Projects 
Castle Cement 
Schenectady 
Rhone Poulenc 
 

HOW MATL CAN HELP YOU with your Process Plant  

From early stages of a concept, MAT Ltd works in collaboration with you as the client to investigate the feasible options to enable a robust evaluation of what may be the best option. Because you are the expert in your product, we do not specialise in any particular process option, but we have access to a wide range of supporting specialist associates who add value to the discussion where needed. 
 
We can then develop your original concept into a workable set of designs that not only give you and your suppliers full visibility and clarity into what these mean, but enable you to engage your team in a common understanding and ownership resulting in delivery of what you expect and heading off potential pitfalls before they are built in. 

EXPERIENCED IN DESIGN AND BUILD  

Our background in controls and automation uniquely allows us to understand multiple processes and bring modules together into a functional system. 
 
We are experienced in Design and Build so we include a focus on the practicality of construction and putting into service so, as an operator, you have a smooth transition to a working and optimised plant. 
 
 
 
 
 
 
 
 
 
 

Case study - Industry Focus 

Process Plant 

Process plant comes in a huge range of scale from chemical plants to small recipe batching, and our unique ability to tease out the detail and communicate with all of the interested parties to reach the ideal solution means we plan in the optimal fit, not just the standard fit. 
 
 
CONSULTANCY SERVICES 
 
 
ENGINEERING SERVICES 
 
 
TRAINING AND DOCUMENTATION 
 

 RECENT MATL PROJECTS in the Process Sector:  

Food Manufacturing 
Hazlewood Foods, Selby 
The control system with ingredient batching, mixing and transfer to packaging, and the installation was planned and designed, and all instrumentation selected and positioned to preserve good hygiene conditions but with easy maintenance for this sauce manufacturing facility in Yorkshire. 
Advanced Gasification 
Bentinck Gasification Plant 
MATL were challenged to develop the control scheme for a unique gasifier pilot process being developed into commercial scale with all of the services and data collection necessary to optimise the operation, and to be involved with developing new material handling methods. 
Resin Reactor 
Schenectady UK, Resin Plant 
This resin manufacturing plant was undergoing a major upgrade from a heavily manual operation to a fully automated recipe batching system to be able to capture the production data and to ensure safety and reliability, including the design and programming of the full functional control system and operator training. 
Food Manufacturing 
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Hazlewood Foods, Selby 
The control system with ingredient batching, mixing and transfer to packaging, and the installation was planned and designed, and all instrumentation selected and positioned to preserve good hygiene conditions but with easy maintenance for this sauce manufacturing facility in Yorkshire. 
 
 
 
Resin Reactor 
slidingRolloverArrow
Schenectady UK, Resin Plant 
This resin manufacturing plant was undergoing a major upgrade from a heavily manual operation to a fully automated recipe batching system to be able to capture the production data and to ensure safety and reliability, including the design and programming of the full functional control system and operator training. 
 
 
Advanced Gasification 
slidingRolloverArrow
Bentinck Gasification Plant 
MATL were challenged to develop the control scheme for a unique gasifier pilot process being developed into commercial scale with all of the services and data collection necessary to optimise the operation, and to be involved with developing new material handling methods. 
 
 
 

 CONTACT US  

We are keen to help you find the right design and engineering solution for your process requirements. 
 
Our engineering specialists will work with you to identify the best engineering process, 
design the most robust solutions. 
 
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