Client Overview
Elmleigh are system integration specialists for electrical and mechanical automation systems, specialising in Food and Drink and Parcel Distribution sectors. A new client in the manufacturing sector approached Elmleigh with persistent issues in their raw materials mixing process. Their existing system relied on level sensors that frequently misread volumes, leading to inconsistent product quality and mechanical failures on the production line.
Challenge
The client’s primary concern was dosing accuracy – particularly with water. Inadequate water levels caused improper product consistency, which in turn led to mechanical strain, increased downtime, and reduced overall reliability of the production line.
Although the initial inquiry focused on hardware upgrades, it quickly became clear that a more integrated and precise solution was needed. Elmleigh was invited to become a strategic partner in solving the problem.
Solution
Elmleigh collaborated closely with Parmley Graham (PG), the client’s technical partner, to define the project scope and technical requirements. Through early meetings and detailed correspondence, PG led the specification of components and helped navigate integration challenges.
“Collaboration was key on this project,” said Luke Shinnie, Process Instrumentation Engineer at PG. “By combining our technical expertise with Elmleigh’s hands-on approach, we were able to overcome the initial challenges and deliver a reliable, high-precision solution.”
Sean Sharp, Automation Sales Engineer at PG, added. “This project is a great example of how strong collaboration and the right technology can transform reliability. By combining PG’s product expertise with Elmleigh’s integration capability, we helped the client achieve precise, repeatable dosing and long-term process stability.”
Elmleigh designed, manufactured, installed, and commissioned a new dosing system using SIWAREX Load Cell technology, replacing the unreliable level sensors. The new system delivered accurate control signals directly into the client’s legacy control infrastructure – achieving seamless integration without major system overhauls.
Implementation
During installation, the team encountered compatibility issues between the load cells and the junction box, as well as discrepancies in weight readings. These were resolved through close collaboration with PG, ensuring the correct components were specified and validated.
“This project pushed us to explore new technologies and integrations,” said Richard Smith, Project Manager at Elmleigh. “The results exceeded expectations – not just in precision, but in operational efficiency and reliability.”
Results
- The impact was immediate and measurable:
- Improved dosing accuracy led to consistent product quality.
- Reduced mechanical strain minimised breakdowns and downtime.
- Enhanced operational efficiency improved overall line reliability.
Ongoing Impact
The success of the project has fostered a lasting partnership between Elmleigh and Parmley Graham. PG continue to provide technical guidance, and the collaboration has opened new opportunities to apply similar technology in other sectors – such as sugar measurement – benefiting Elmleigh’s broader client base.
Get in Touch
To discuss how the PG team can help, either email us at support@parmley-graham.co.uk or call 0191 478 0404.
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