Case Studies

Recycling center (Scotland)

Upgrading Waste Detection System for Enhanced Reliability and Safety

BIA Engineering Ltd was engaged to design and implement substantial upgrades to the waste detection system at a major recycling centre.

Project objectives:

Improve reliability of waste detection
Ensure waste remained safely confined within the hopper system
Integrate seamlessly with existing control infrastructure

Our solution included:

Designing and manufacturing a new removable metal door with replaceable windows
Developing and installing a new advanced instrument detection system
Ensuring full compliance with BS7671 standards
Integrating the new system with the existing DCS infrastructure
Conducting rigorous commissioning and testing to ensure system reliability and repeatability

Outcome:

The project demonstrated BIA Engineering Ltd’s expertise and versatility in managing complex upgrades. Our adherence to safety and quality standards, combined with a collaborative commissioning approach, delivered a successful and reliable system enhancement.

Energy recovery facility (East Scotland)

Redesign of Waste Grab Control System for Enhanced Safety and Diagnostics

BIA Engineering Ltd was engaged to resolve persistent issues with the waste grab control system at a major energy recovery facility.

Project objectives:

Eliminate frequent faults and breakdowns caused by insufficient failsafes
Reduce risk of damage to large mechanical components
Improve operator visibility and system diagnostics
Enhance system resilience and self-protection capabilities

Our solution included:

Complete redesign of the waste grab control system, addressing all potential fault scenarios
Installation of enhanced visual diagnostics via panel indicators, enabling operators to identify and respond to faults without unnecessary callouts
Implementation of automatic system cut-outs to proactively prevent damage from recurring issues
Development and use of a full test rig to validate system modifications before live deployment
Phased installation (one grab at a time) with iterative adjustments based on feedback and testing
Empowering the system to self-protect, reset autonomously, and provide detailed fault communication to the control room — eliminating unnecessary entries into the waste bunker

Outcome:

The project significantly improved system reliability, safety, and operator control. BIA Engineering Ltd’s structured approach and engineering expertise delivered an outcome that exceeded client expectations and enhanced long-term plant performance.