Osprey Electrical Engineering Ltd Detailed Case Study – MDL
Project Overview
Osprey Electrical Engineering Ltd was appointed by MDL to support the relocation and expansion of a major automated production and distribution operation within their Pontarddulais facility.
The project involved osprey being awarded the design, consultancy, enabling works, and full electrical installation associated with a new production area and large-scale conveyor and automation systems integration spanning their vast facility.
Initially appointed to deliver the electrical design and consultancy package, Osprey’s involvement quickly progressed into the full installation package following the confidence built with the client during the early planning and coordination stages.
This project demonstrates Osprey’s capability to operate within complex live industrial environments, coordinating around multiple contractors, automation specialists, production constraints, and programme-critical installation phases.
Project Background
MDL initiated a major long-term investment programme to modernise and future-proof its material handling, automation, and conveyor systems across the site.
As part of a wider multi-million-pound investment into the facility, MDL commenced the phased replacement and upgrade of its automation and material handling systems throughout the site.
Osprey Electrical Engineering Ltd was appointed as the electrical contractor responsible for delivering the complete electrical infrastructure package to support the new installation works.
This included:
- Full design package
- New electrical distribution infrastructure
- Industrial containment systems throughout the facility
- Small power and lighting installations
- Power supplies to new automation and material handling equipment
- Infrastructure to support conveyor systems, PLC panels, and associated control equipment
- Coordination with multiple specialist contractors and automation providers
The project is being delivered within a live operational environment over an estimated 9-month programme, with completion targeted for February 2027.
Project Scope:
MDL, Lye Industrial Estate, Pontarddulais, Swansea
Project Elements:
• New mezzanine production and automation area
• New power distribution infrastructure
• Conveyor and automation electrical infrastructure
• Lighting and emergency lighting systems
• Small power and network infrastructure
• Control panel feeder supplies
• Industrial containment systems
• High-level cable routing across live facility areas
• Coordination with automation and conveyor specialists
The works involved substantial electrical infrastructure upgrades to support the client’s expanding automated warehouse and distribution operations.
Design & Consultancy Phase
Osprey was first appointed on a consultancy basis to assist with the electrical design strategy, installation sequencing, and infrastructure planning for the project.
This early-stage involvement included:
Reviewing automation and production requirements
Designing new sub-main distribution arrangements
Coordinating containment strategies
Supporting value engineering exercises
Advising on programme sequencing and installation practicality
Identifying future installation risks before construction
A key part of Osprey’s involvement was simplifying and rationalising installation methods to improve programme efficiency and reduce unnecessary cost without compromising quality or future scalability.
Examples included:
• Revising containment strategies from heavy trunking systems to more efficient basket containment solutions
• Simplifying lighting infrastructure layouts
• Supporting phased installation strategies to minimise disruption to live operations
This proactive approach during the design phase established Osprey as a trusted delivery partner rather than simply an installation contractor.
Infrastructure & Installation
Following successful completion of the consultancy and planning stages, Osprey was awarded the full installation package.
The electrical infrastructure delivered as part of the project included:
• New distribution boards and sub-main supplies
• Installation of 95mm² 5-core SWA sub-main cables
• Heavy-duty containment systems across large industrial areas
• High-level cable tray and basket systems
• Power infrastructure for automation and conveyor systems
• Supplies to multiple PLC control panels
• Lighting and emergency lighting systems across mezzanine levels
• Extensive small power and data installations
The installation included infrastructure supporting:
• Goods-to-person stations
• Conveyor systems
• Adapto automation systems
• SCADA stations
• QA stations
• Packaging and dispatch systems
• Reporting dashboards
• Maintenance and operator stations
• Wireless network infrastructure throughout the mezzanine and warehouse areas.
Live Industrial Environment
One of the major challenges of the project was delivering significant electrical infrastructure upgrades within a live industrial and logistics environment.
Works were coordinated around:
• Existing production activities
• Automation installation programmes
• Conveyor installation sequencing
• Multiple contractor interfaces
• Restricted access areas
• Tight programme constraints
The installation strategy required careful planning to ensure works could progress safely while minimising disruption to ongoing site operations.
This included:
• High-level installation works using MEWPs
• Weekend and phased working strategies
• Detailed shutdown planning
• Temporary sequencing arrangements
• Multi-trade coordination meetings
Osprey worked closely with the client and wider project team to ensure critical programme milestones could be achieved.
Outcome
The MDL project demonstrates Osprey’s ability to successfully deliver complex industrial electrical infrastructure projects involving:
- Large-scale industrial power distribution
- Automation and conveyor integration
- Design and consultancy support
- High-level industrial containment systems
- Live production environments
- Multi-contractor coordination
- Programme-critical delivery
The project reinforced Osprey’s position as a contractor capable of delivering technically demanding industrial and automation infrastructure projects while supporting clients from concept and planning through to final installation and commissioning.
