Engineering & Planning
Client consultation · machine loads · maximum demand · available capacity · layouts · distribution planning
Industrial electrical case study
Dewhurst ManufacturingFacility Consolidation
Electrical Engineering, Machinery Integration &
Commissioning
Moorebank, NSW
When Dewhurst consolidated two manufacturing operations into one new facility, Braintric worked from planning and engineering through electrical construction, machinery integration, testing and commissioning—helping transform the new location into an operational manufacturing facility.
ClientDewhurst
LocationMoorebank, NSW
Project typeManufacturing Facility Consolidation
SectorLift Component Manufacturing
Duration6 Weeks
DeliveryEngineering to Commissioning
35Machines
8Production Lines
5New Distribution Boards
600 m120 mm² Single-Core Cable
1,400 mMachinery Cabling
1,500 mData Cabling
20CCTV Cameras
6 WeeksProject Delivery
Client & project context
Two Manufacturing Operations. One New Facility.
Dewhurst is an international manufacturer and supplier of components for the lift industry, with operations including Australia.
The Australian operation was consolidating two existing factories into a new manufacturing facility in Moorebank, NSW. Relocating equipment was only one part of the challenge: the new facility needed infrastructure for approximately 35 machines across eight production lines, together with distribution equipment, extraction systems, controls, communications and CCTV.
Braintric approached the facility as an integrated industrial electrical system—not a series of isolated machinery connections.
The challenge
Engineering a New Electrical Environment for Existing Production Equipment
Each machine had its own power requirements, operational characteristics and relationship with the wider production process. The new electrical system needed to accommodate large machinery loads while maintaining appropriate distribution, protection and capacity across the facility.
Machinery positioning, production-line layout, switchboard capacity, maximum demand, submains, cable routes, controls, extraction and communications all had to be considered together. Existing PLC interfaces and variable-speed drives also required assessment, reconfiguration or recommissioning.
Engineering & planning
The Project Started Before the First Cable Was Installed
Braintric held technical meetings with the Dewhurst team to understand the manufacturing process, machinery requirements and planned operation of the new facility. Individual machine loads and current requirements were assessed alongside available electrical capacity and maximum demand.
Machinery positions and production-line layouts were considered with switchboard locations, distribution requirements, submains and cable routes. Braintric then presented the proposed electrical solution, scope and quotation before construction proceeded.
- Client consultation
- Site & load assessment
- Maximum demand
- Electrical design
- Construction planning
Electrical infrastructure
Building the Electrical Backbone
Five new distribution boards, new submains, machinery power supplies and extensive industrial containment were delivered across the production areas.
Approximately 600 metres of 120 mm² single-core cable formed part of the larger distribution works, together with approximately 1,400 metres of cabling serving machinery and production equipment.
The electrical backbone had to maintain practical routing, accessibility and coordination across approximately 35 machines while fitting the physical production environment.
Machinery integration
35 Machines. Eight Production Lines.
The objective was not simply to energise individual equipment, but to return complete production systems to operational readiness.
CNC machineryLaser machineryPress machineryWelding equipmentPaint booth systemsExtraction equipment
Braintric provided the electrical supplies and connections required for the equipment and supported machinery-control integration, including PLC-related interfaces, VSD reconfiguration, fault finding and recommissioning where required.
Controls, VSDs & recommissioning
More Than Power Connections
Industrial machinery relocation frequently involves controls configured around the previous operating environment. Braintric supported control-interface assessment, variable-speed drive configuration, fault finding and integration of supporting equipment such as extraction systems.
Managing infrastructure and machinery integration within the same project reduced the separation between building electrical works and production-equipment requirements.
Data & CCTV infrastructure
Power, Communications & Site Infrastructure
The scope extended beyond machinery power and distribution. Braintric delivered approximately 1,500 metres of data cabling throughout the facility and installed a 20-camera CCTV system.
Coordinating electrical, communications and security infrastructure allowed multiple essential building systems to progress as part of the facility consolidation rather than as isolated installations.
Testing & commissioning
From Installation to Operational Readiness
Braintric progressed through verification, testing, fault finding and commissioning of the new electrical infrastructure, machinery connections, controls and associated equipment, including VSD reconfiguration and recommissioning where required.
With approximately 35 machines and eight production lines, commissioning was coordinated around the broader relocation program and dependencies between equipment. Braintric remained involved from the original engineering discussions through construction and into operational readiness.
Project delivery
Engineering and Construction Working Together
The approximately six-week project was delivered by one electrical engineer, one project manager, three electricians and five apprentices.
Braintric’s role across planning, electrical installation and commissioning provided continuity and enabled technical issues identified during construction or recommissioning to be addressed within the wider system context.
1 Electrical Engineer1 Project Manager3 Electricians5 Apprentices
Project scope
One Coordinated Industrial Delivery Scope
From early technical consultation through final operational support.
Power & Distribution
Main infrastructure · switchboards · five distribution boards · submains · machinery supplies · protection
Machinery & Controls
CNC · laser · press · welding · paint booth · extraction · PLC interfaces · VSDs · recommissioning
Industrial Infrastructure
Cable tray · containment · 600 m main cable · approximately 1,400 m machinery cabling
Data & Security
Approximately 1,500 m data cabling · 20-camera CCTV system · network and CCTV infrastructure
Commissioning
Electrical and machinery testing · fault finding · control checks · recommissioning · final support
Outcome
One Facility. Integrated Electrical Infrastructure.
The project brought the electrical requirements of two former manufacturing operations together within one new Moorebank facility.
Braintric delivered the distribution, machinery infrastructure, controls support, data and CCTV systems required for the consolidated manufacturing environment. Most importantly, the electrical infrastructure was developed around production requirements from the planning stage—not added after machinery arrived.
Project photo story
From Empty Facility to Operational Environment
A visual sequence of infrastructure, machinery integration and project delivery.
Related capabilities
Related Industrial Solutions
The infrastructure delivered in this project also demonstrates capabilities that support future connected-energy projects.
Future smart-energy pathway: This project delivered industrial electrical, machinery, controls, data and CCTV infrastructure. Braintric can also assess energy metering, Energy Management Systems, solar PV, commercial battery storage, demand management, load optimisation and equipment-level energy visibility for suitable facilities; these systems are not claimed as part of the Dewhurst project.
Industrial projects start with the brief
Planning a Factory Relocation or Industrial Electrical Project?
Whether you are relocating machinery, expanding production, upgrading a factory or planning a new manufacturing facility, Braintric can assess the electrical requirements and develop infrastructure around your operation.