Muffett Gears, Tunbridge Wells

This was a very interesting request we had from our customer, Muffett Gears in Tunbridge Wells.

They are an engineering company and had ordered a very specialist piece of equipment that measures components to within a micron. They needed us to build a special laboratory to house their new plant.

Below are some of the pictures of the project taking shape – please read below for full details.

Here is the space before we started work.

The Organisation

Stanley Herbert Muffett founded the business of S H Muffett in 1920. The business was originally automotive engineering and then general machining. By the early 1950’s Stanley recognised the opportunity for the manufacture of high quality gears. Today, Muffett Gears manufacture some of the highest quality precision gears, used in demanding applications their customers include; aerospace, medical, automotive, marine and hydraulics.

The Quality Department is responsible for maintaining and enhancing ISO 9001:2008 and aerospace ISO 9100:2009 quality standards and to achieve even more exacting standards the company purchased the latest Zeiss measurement centre. The Zeiss measurement centre can achieve an accuracy of 1micron (a human hair is 150 micron).

The Challenge

To accommodate a new Zeiss measurement centre and provide a larger facility for inspection and quality assessment a new facility would be needed. The Zeiss required a ceiling height of 3.3 metres, a level floor and dedicated power supply. Additionally, to achieve operational measurement accuracy the Zeiss required a constant ambient temperature with variance of plus or minus 1°C.

The Solution

The new Quality Department was constructed in the rear of one of the factory units. To achieve a fully enclosed facility a ceiling comprised of a steel frame face with plasterboard was suspended from the roof purlins at 3.5 metres. The underside of was clad with 50mm Celotext insulation boards. A further Armstrong suspended ceiling was installed below with a void for air conditioning pipework and recessed light units. Also, in the void on the Armstrong ceiling tiles there are insulation bags providing further insulation.

The stud and plasterboard wall was constructed to a height of 3.6 metres. The construction consisted of 12.5mm sheets of plasterboard either side of a 50 mm steel stud. The 50mm void was filled with an insulation quilt. The factory unit walls were dry lined with wall liner studs and the void filled with insulation and then plasterboard clad.

The structure included a Hospital door set with detachable over panel to allow the Zeiss to be installed and large double glazed uPVC windows for ingress of natural light. The fit out included commercial vinyl floor covering and fitting bespoke work benches.

For power, a new local submain was provided with a distribution board, allowing the Zeiss to have a dedicated power circuit. The perimeter walls were fitted with 3-compartment uPVC dado trunking and power and network connections were distributed throughout.

Heating and cooling is provided by a Toshiba heat pump system. The indoor units were mounted at high level and the condenser units were located on the internal factory wall at high level.

The Result

This bespoke project was completed on time in six weeks allowing the installation of the Zeiss measurement centre shortly after completion.