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When constructing a modern high-speed flour mill, efficient installation and long-term maintenance of plant equipment demand a carefully planned lifting solution. For a recent project, the main contractor turned to Hoist & Winch Ltd, one of the UK's leading lifting equipment companies. Hoist & Winch specified, supplied and installed a two-phase hoisting solution capable of supporting both the plant installation phase and ongoing maintenance activities once the facility became operational.

The project required a flexible approach. During installation, contractors required a high-capacity hoist capable of lifting heavy process equipment through a dedicated lift shaft. Upon completion of plant installation and commissioning, however, the requirement shifted to a permanent, high-speed lifting solution to support routine maintenance of the mill’s processing equipment.

Following site meetings and consultations with plant designers and project managers from the main contractor, Hoist & Winch proposed a turnkey lifting package that could meet both requirements.

For the short-term installation phase, Hoist & Winch supplied a 10t safe working load (SWL) JDN air-powered chain hoist offering 30m of lifting height. Mounted in an air motor-powered trolley, the hoist was complemented by a portable diesel-powered air compressor and air hoses. Hoist & Winch also undertook installation and commissioning of the hoist, along with load testing and LOLER certification of the customer’s pre-installed hoist runway beam. Operator handover training was subsequently provided for plant installation contractors.

Installing the temporary hoist system formed phase 1 of the project. To facilitate this work, the site scaffolding contractor constructed a platform over the lift shaft in accordance with Hoist & Winch specifications. The 10t air-powered hoist unit was raised to installation level using a temporarily mounted 2t SWL JDN air-powered chain hoist fixed to the underside of the runway beam.

Once positioned beneath the beam, installation of the 10t hoist took place using a dedicated lifting arrangement comprising a pair of T-shaped lifting frames and four 1t SWL manual chain blocks. This configuration enabled engineers to mount the hoist trolley safely to the runway beam by initially opening and then closing the trolley width around the beam section.

Following installation checks and connecting the air supply, Hoist & Winch performed dynamic load testing of both the hoist and runway beam using a 10t test load over the full 30m lifting height. This process was followed by a 125% static proof load test at low level. With testing successfully complete, Hoist & Winch delivered operator handover training to the installation contractors responsible for lifting the mill’s process plant equipment into position.

Phase 2 of the project involved removing the temporary air-powered hoist and installing the permanent lifting solution: a 3.2t SWL Stahl electric wire rope hoist with 30m lifting height. Mounted on a motor-powered trolley and operating with a single rope fall, the hoist unit delivers a very high main lifting speed of 16 m/min to minimise plant downtime during maintenance lifts through the access shaft and 2.6 m/min slow lifting speed for precise load laydown at the load landing level.

Hoist & Winch conducted installation, commissioning, load testing and LOLER certification of the permanent hoist system, before providing handover training for the mill’s maintenance personnel.

“Projects like this demonstrate the value of careful planning and technical collaboration to deliver safe, efficient lifting solutions that support both the construction and long-term operation of complex industrial facilities,” says Hoist & Winch Director Andy Allen. “We subsequently secured the contract for annual hoist inspection and maintenance.”

Visit www.hoistandwinch.co.uk for further information and to view recent case studies.