JR Revell supported Amari Plastics with the electrical design and installation for their relocation into a new warehouse facility in East London. The move involved transferring live production operations from an existing site into a new CAT A unit with only basic electrical infrastructure in place.
The challenge was maintaining production throughout the move. Machinery, staff and processes all needed to be transferred in a tightly controlled sequence, with no interruption to output. Any delays or installation issues would have had a direct impact on operations and programme.
JR Revell got involved early, surveying both sites and planning the relocation around production requirements. The focus was on sequencing the move correctly and delivering a power distribution system that would support machinery from day one, rather than requiring rework later.
The solution centred on designing the system around the machinery layout. Separate electrical distribution boards were installed to divide building services from machinery supplies, improving safety, clarity and day-to-day operation. Cable containment systems and power routes were planned in advance to ensure efficient installation and long-term usability.
JR Revell delivered a full electrical installation, including new distribution boards, armoured cabling on cable tray systems, and power supplies for machinery, isolators and commando sockets. LED lighting systems were installed, in co-ordination with new racking layout, to meet required lux levels, with automated controls introduced to improve energy efficiency. All systems were fully tested and commissioned.
Both facilities remained live throughout, requiring close coordination with the client, other trades and machinery suppliers. Works were aligned with production schedules to ensure a smooth transition.
The project was completed within a three-week programme, enabling a seamless move between sites. Production continued without interruption, and the new facility was fully operational from day one.
This project demonstrates JR Revell’s ability to deliver industrial electrical installations in live environments, combining planning, coordination and practical design to keep operations moving.
Design Insight
Design Manager – Bryan Stanford
The electrical design for this project was delivered in-house by JR Revell, including full schematic drawings and load calculations to support both warehouse lighting and machinery power requirements.
Working closely with the project manager throughout delivery, the design was developed alongside live site information to accurately determine cable routes, lengths and circuit loads. This integrated approach ensured the installation was compliant with BS 7671 and fully aligned with the operational needs of the facility from day one.
Client Feedback
“I think being that it was Tom’s first job as PM, he’s done a great job, so thank you. Brad who was on site for most of the job also did a cracking job, the boys are a credit to you. Overall mate, really happy, really pleased I went with you guys; proper professional job.”
James Degiorgio, General Manager, Amari Plastics
Scope of Works Delivered (using trusted manufacturers including Hager and Collingwood):
- Installation of Hager distribution boards, including a 250A board for machinery supplies and a 125A board for building services, creating clear separation between plant and general power
- High-level cable containment and armoured cabling systems to support efficient and durable power distribution across the warehouse
- Installation of Collingwood high bay LED lighting within racking areas, designed to achieve required lux levels and align with the warehouse layout
- Collingwood non-corrosive, vapour-proof lighting installed within plant areas to provide a robust solution suited to the environment
- Automated lighting controls using PIR sensors to improve energy efficiency and day-to-day usability
- Emergency lighting system installed and tested in accordance with BS 5266 requirements
