Forged Innovation
Services

From Problem to Revenue

Design, fabrication, assembly, wiring, testing and commissioning by one team.

  1. Problem
    01Problem

    We start on site, with your material in hand.

  2. Concept
    02Concept

    Layouts and options sketched and costed before detail design.

  3. Design
    03Design

    3D models, calculations and detailed design.

  4. Fabrication
    04Fabrication

    Cut, folded, welded and finished.

  5. Assembly
    05Assembly

    Drives, bearings and seals fitted and aligned.

  6. Wiring & controls
    06Wiring & controls

    All wiring and testing completed in-house.

  7. Testing
    07Testing

    All machines fully tested electrically and mechanically before leaving the workshop.

  8. Install & commission
    08Install & commission

    Installed, commissioned and handed over on site.

Start here

Material Handling Audit

A fixed-price site visit and written report. We watch your plant run, measure the material, find the bottlenecks and recommend fixes with budget costs.

  • Half-day site visit by an engineer
  • Material assessment: bulk density, moisture, flow behaviour
  • Written report with prioritised fixes and budget prices
Book an audit
EXAMPLE AUDIT · LINE 1Assessed stateFlow: intermittentFixes implementedFlow: steady HOPPERAUGERQUENCHBAGGING 123 1Hopper bridges on wet feedstockLive bottom + agitator2Auger undersized for bulk densityResize screw and drive3No weight or moisture recordLoad cells + data logger
EXAMPLE PROCESS · HEAT & CHAR Stage 1 of 4ConceptStage 2 of 4Mass & energy balanceStage 3 of 4Detail designStage 4 of 4Controls & validation FEED REACTOR COMBUSTION HEAT EXCHANGER STACK HEAT USERS BIOCHAR ~450 °C~950 °C~180 °C80 °C60 °CQ ≈ 1 MWreactor heating PLC PTTTTTFT CONCEPTBALANCEDETAILCONTROLS
Process engineering

Heat and Mass Balance Design

Beyond single machines, we develop complete thermal processes: from the first mass and energy balance, through heat exchanger and pipework design, to the controls that keep the process stable. It is how we built ZEDE.

  • Mass and energy balances for your feedstock
  • Process flow diagrams and P&ID development
  • Heat exchanger, hot-gas and high-temperature pipework design
  • Instrumentation, control philosophy and PLC logic
  • Built, tested and commissioned in-house
Wiring and controls

Panel build and logic

We take our fully defined Functional Design Specification (FDS) and use it to guide the full panel build, implementing our development process, control logic and defined instrumentation to leave a fully turnkey, automated system.

PLC input and output modules wired in a control panelControl panel with network switch and power suppliesTerminal rails and cable marking inside a panel
Material handling and pre-conditioning

Upgrading low-value feedstock to fuel grade

Where we really excel is handling and upgrading low-grade, wet and inconsistent material. We have run poultry litter, poultry manure, digestate from a range of feedstocks, other challenging organic feedstocks, and wood through our own plant.

Heat recovery

Heat exchangers for biomass and pyrolysis

Flue-gas-to-water shell and tube exchangers, condensers and dryer heat exchangers for low-pressure hot water systems. Higher-pressure and thermal-oil duties by enquiry.

Emissions

Scrubbers and high-temperature pipework

Ammonia scrubbing developed through government-funded contracts, plus high-temperature pipework.

ESU exhaust scrubber units →