Retrofit solution for ageing alarms at cereal manufacturing facility

Legacy alarm specialist Omniflex has delivered a direct retrofit solution for ageing MPAS 90 alarm systems at Kellanova’s Wrexham facility, replacing obsolete units with its SIL-1 rated Omni16R rack-based alarm logic and Omni-X LED Displays. The upgrade modernises a number of legacy alarm systems, that are nearing end-of-life, while retaining existing panel space and wiring to minimise engineering changes and disruption. Designed to meet current safety guidelines, the new installation enhances the reliability and monitoring of critical substation processes across the site.

Kellanova Wrexham, the world’s largest producer of Special K cereal, is a major cereal manufacturing facility in North Wales. Across the site, there are three substations that previously relied on Highland MPAS 90 rack-based alarms to monitor fault conditions of critical processes. However, the original manufacturer of these systems has long since gone out of business, making replacement parts and technical support difficult to access.

So, when the out-of-date MPAS 90 units began to reach the end of their service lives, Kellanova turned to Omniflex for help. After conducting a site survey on the annunciators, Omniflex’s engineers provided an upgrade using the company’s Omni16R unit and Omni-X displays as a direct retrofit, using the existing space and hardwired connections.

“Work began at Substation one initially, which was completed successfully and now the upgrade of Substation two is in progress, with Substation three to shortly follow,” explained Darren Barratt, Sales Manager at Omniflex. “The Omni16R and Omni-X units provided for Kellanova reliably monitor electrical substation alarms, such as those reporting on transformers and circuit breakers.

“The Omni16R and Omni-X provides a cost-effective direct upgrade of MPAS 90 alarm systems with minimal operational disruptions. By using the existing panel space and wiring, it saves any costly engineering reconfiguration and enables a smooth transition,” continued Barratt.

Omniflex provides a free legacy alarm upgrade consultation service, so site managers can get the advice they need on the status of their alarm units relative to safety guidelines and best obsolescence management practice.