Farrat isolate multiple machines across the production line at new £1bn automotive manufacturing facility in Slovakia

The recent €1.4bn (£1bn) investment into the new manufacturing facility in Nitra, Slovakia, marks the first time a UK automotive company has opened a plant in the country.

The 300,000m² facility stands at the forefront of aluminium manufacturing and engineering expertise in Slovakia and has been designed with the flexibility to enable smart, connected manufacturing technologies that will support improved process efficiency and deliver up to 150,000 vehicles a year.

Farrat worked with the Structural Engineer and Project Personnel to ensure that a variety of machines within the plant were sufficiently isolated and capable to inspect at high speed with precision.

This included engineering and bespoke-manufacturing components for several vibration isolation systems for robot mounted non-contact sensor systems, CMM’s and Presses across the production line.

Construction of a machine isolation pit using Farrat ISOMAT materials

Farrat ISOFOAM120 was installed on the walls of machine foundations to provide lateral isolation. This system is typical where a high stiffness foundation is critical but a degree of active or passive isolation is required, even if only from the risk of random events such as dropping heavy items nearby.

Over 1,000 ISOMAT pads of various rubber compounds and sizes, were then used to fine tune dynamic natural frequencies and stabilise each machine for optimum performance.

Farrat ISOMAT Foundation Isolators are the cornerstone of Farrat’s Isolated Foundation Solutions. Our ISOMAT pads have a unique profile coupled with a selection of our elastomers and thicknesses.  Due to extensive testing and experience, Farrat ISOMAT pads deliver highly predictable performance characteristics over many years of service.

Farrat ISOMAT is produced in 3 elastomeric types: IMBR, IMCR and IMNR.

Installation of Cupper Press Isolated Foundation
Farrat ISOMAT Isolated Foundation during construction

Large automotive manufacturers and leading OEM’s are increasingly designing facilities and machinery to work faster and with more precision, whilst reducing weight and cost.

Farrat Isolated Foundations are consequently integrated into factory design to ensure that the operating conditions (in terms of vibration levels) are controlled to within equipment specifications, to maximise productivity and conform to H&S and local authority requirements.

Whether you are relocating existing machinery, installing new equipment or are involved in detailing foundations, Farrat have the knowledge and experience to provide the right Isolated Foundation solution for your production facility.

Farrat has designed and delivered industrial vibration control solutions for many of the world’s largest and most complex projects in the automotive, canning and aerospace markets. Whether you are relocating existing machinery, installing new equipment or are involved in detailing foundations, Farrat have the knowledge and experience to provide the right Isolated Foundation solution.

For further information:

60 Years of Farrat – Gareth’s Story

Gareth's Story - Celebrating 60 Years of Farrat

PEOPLE PROFILE:

FARRAT PRODUCTION MANAGER, GARETH HOGBURN

Areas Of Expertise: LEAN Manufacturing, Production, Tooling, Rubber Molding, Waterjet
Education: Fellow Of The Manufacturing Institute
Time at Farrat: 21 Years

Tell us about your background?

I joined Farrat in 1997 as an apprentice on a 5 year scheme whilst attending college at North Trafford, where I studied NVQ 2, 3 and 4 followed by an HNC, in Engineering. During my apprenticeship I learn’t how to operate the milling machine and lathes for the production of industrial anti-vibration machine mounts. I was in a production team of four at this time and have fond memories of learning how to manufacture raw castings all the way through to finished product, including welding and spray. As a small team, we worked really hard to meet the demand and collaboration was really important to making this happen – as a result, we became good friends and are still good friends now.

Gareth's Early Days at Farrat

Gareth pictured on the right during his early days as an Apprentice at Farrat

I completed my apprenticeship in 2002 and remained at Farrat, moving into new production avenues as the product portfolio expanded. Farrat moved into the rubber molding market to produce vibration isolation and acoustic isolation solutions for the construction industry, so I was trained how to operate presses and moved over to the press shop. This was a great experience for me and allowed me to continue learning new production methods and was able to input into the new processes that followed. I worked in the press shop for around 10 years and saw the company scale it’s manufacturing facilities, with the introduction of several new presses and a much larger production team.

I became Production Team Leader in 2014 and began my LEAN Fellowship with The Manufacturing Institute through Farrat, which is where I really learn’t about continuous improvement. I completed my LEAN Fellowship within two years and am now Production Manager at Farrat and ‘Champion of Continuous Improvement’.

Why Farrat?

At school I always wanted to be a mechanic as I loved cars.

I was set to go to college and study mechanics, until one GCSE lesson when a teacher inspired me to change my path. It was during Design Technology when I designed a bike rack to fit on the back of a mountain bike as part of my coursework. My Design Technology teacher came over and said “Gareth, this is fantastic. I know that you’ve put on your careers form that you want to be a mechanic, but have you thought out a career in engineering?”.

He took me to one side and explained to me the type of roles and industries that engineering covers and the opportunities it could open up. It really inspired me to be ambitious, so I changed my college course to engineering.

Gareth collecting his LEAN Fellowship from The Manufacturing Institute

Gareth collecting his LEAN Fellowship from The Manufacturing Institute

I researched engineering and manufacturing firms in the area before college and Farrat stood out to me. I interviewed at Farrat and a tooling firm not far away. When I was offered the apprenticeship at Farrat I finally took it.

I’ve now been here at Farrat for 21 years and really enjoy it.

We’re a close knit team who take care of each other. Everyone is of the same mindset that quality is crucial and we all dig in deep to get a project over the line for the customer, even if it means working weekends and evenings.

Farrat has enabled me to learn and develop new skills and grow within my production role. I’m treated with respect and shown opportunities by people at all levels in the business, which is really important to me.

Do any of the projects that you have worked on stand out in your memory?

The big construction projects started to come through in around 2012, which was a huge learning curve for us as a company, as we hadn’t worked on these types of projects before. The first project of this nature was in London, which sticks in mind as it created so many challenges for us. It was a very large and technically challenging building isolation project.

However, the solutions and manufacturing processes that we put in place for that early project were the cornerstone of what we do today, so really it acted like a large scale R&D project. Ever since then, we’ve completed several large scale construction projects without any major hurdles. So we have a lot to thank that project for!

What are you working on at the moment?

At the moment the production team are working on some large building vibration isolation projects located in London, several cinema isolation projects in the UK, U.A.E and Saudi and a few impressive isolated foundation projects for the canning sector in Europe. Alongside this we are producing industrial anti-vibration machine mounts for clients in the power gen sector, so busy all round!

Myself personally, I am rolling out new LEAN practices across the company (not just within production), continually improving and streamlining Farrat’s processes.

What do you see Farrat focusing on in the coming years?

Alongside LEAN and SMART changes to how we operate, I also see product diversity playing a major role. We are a company who pride ourselves on being a solution provider, not just a product manufacturer. We’ve invested heavily in R&D over the last few years and are seeing some fantastic innovations coming through as a result, which will no doubt feed into our existing product range but also inform new solutions for our primary markets.

I’m excited to be part of that journey and come up with smart solutions to the production challenges that those product innovations may bring.

If you would like to hear more about Production opportunities at Farrat, visit our Careers Page.

Alternately, get in touch with Gareth on: +44 (0) 161 924 1600.

Farrat CineFLOOR PRO used to isolate the first cinema ever constructed in Jeddah

Red Seal Mall, Jeddah
Red Seal Mall, Jeddah - IMAX

The first cinema ever to be built in Jeddah opened its doors yesterday at Red Sea Mall, fully acoustically isolated using Farrat CineFLOOR PRO systems.

The VOX Cinemas multiplex is owned by Majid Al Futtaim and has a capacity to seat an audience over 1,400 people.

The Red Sea Mall cinema features 12 screens in total, including Saudi’s largest IMAX viewing experience and three GOLD by Rhodes – a new dining concept where cinema guests can order gourmet meals directly to their cinema seats.

Farrat was contracted to design, manufacture and supply CineFLOOR PRO isolation systems for each auditorium following recent successes acoustically isolating similar VOX cinemas at The Mall of Egypt and City Centre Sharjah.

As our most frequently specified grade of acoustic floating floor, CineFLOOR PRO suffers no compromises from low mass or high stiffness isolators to achieve the high acoustic isolation performance standards required by VOX.

Full Case Study on VOX Red Seal Mall to follow.


Farrat has designed and delivered acoustic isolation solutions for many of the world’s largest and most striking multiplex cinema projects and the Building Acoustics team at Farrat has decades of experience creating state-of-the-art acoustic environments within cinemas.

For further information:

The ultimate acoustic isolation grade for a new generation of 4DX Cinemas

CineFLOOR MAX-teal

We are pleased to bring to market our highest-performance and most advanced grade of commercial floating floor yet: CineFLOOR MAX.

Engineered to meet the specific and rigorous acoustic demands of 4DX auditoria, the new CineFLOOR MAX system incorporates high damping isolators to control and constrain vibration, while still providing exceptionally high levels of sound insulation performance.

Development of the CineFLOOR MAX system began following Farrat’s role in the design, supply and installation of the new Cineworld Bracknell – one of the first purpose built 4DX Cinemas in the UK – as well as several years of research into cinema motion technology. 

CineFLOOR MAX - 3D section render with labels

MAX System Features:

CineFLOOR MAX is future-proofed using the most extreme calibration routines from 4DX suppliers.

The MAX system not only isolates the vibration from adjacent auditoria, but also controls the slab response that the 4DX seats are mounted to, offering superior motion feedback and a more immersive 4D experience.

CineFLOOR MAX floating slabs can be designed with a fully fibre reinforced concrete to allow easy seat installation without the risk of hitting the rebar and self-compacting concrete can also be used to ensure high flatness tolerance is achieved, to allow vinyl or carpet to be laid directly on top of it.

 

MAX Design Details:

 

MAX Grade Suitability:

CineFLOOR MAX sits at the top end of the CineFLOOR range, engineered to provide the highest levels of acoustic isolation performance for the most demanding cinema applications – predominantly 4DX and multiplex cinemas. Our ultimate aim for CineFLOOR MAX is to enhance movie-goers’ 4DX experience and maximise value/impact for cinema developers.

To identify which grade of CineFLOOR is right for your auditorium, use our suitability table here.


Farrat has designed and delivered acoustic isolation solutions for many of the world’s largest and most striking multiplex cinema projects and the Building Acoustics team at Farrat has decades of experience creating state-of-the-art acoustic environments within cinemas.

For further information on CineFLOOR MAX, or to discuss a project, Contact Farrat Building Acoustics Team.

Farrat Thermal Breaks reduce energy loss in London’s new ‘City Cluster’

Londons new City Cluster

22 Bishopsgate is one of 13 major build projects expected to change London’s skyline by 2026.

Designed by PLP Architecture, 22 or ‘Twentytwo’ Bishopsgate stands  278 metres tall as the City of London’s tallest tower within the financial districts new ‘City Cluster‘. The tower provides over 1.2 million sq ft of office space and can accommodate up to four tenants on each of the 62 floors.

Over 17,000 tonnes of superstructure structural steelwork and metal decking was designed and fabricated for construction by Severfieldwho approached Farrat during fabrication to supply a suitable solution to mitigate against thermal bridging between connections.

Superelevations, axial shortening and complex geometrical dilemmas presented challenges on this project, so Farrat worked closely with Severfield to manufacture a package of structural thermal breaks in various sizes, shapes and thicknesses to fit seamlessly into design details and meet specification.

Farrat’s load-bearing structural thermal break material with the highest levels of compressive strength and thermal insulation, was used between steel-to-steel connections to prevent thermal transfer from the exterior of the structure into the internal structure via the steel framework.

Farrat thermal break plates were also used in steel-to-concrete applications to greatly reduce heat loss into the concrete slab, providing better insulation for the structure overall.

22 Bishopsgate during construction with Farrat Thermal Break in-situ, courtesy of Severfield
22 Bishopsgate during construction with Farrat Thermal Break in-situ, courtesy of Severfield

For in-depth technical information on all our grades of thermal break materials, please head over to our Thermal Breaks page, or alternatively you can contact us.

‘Twentytwo’ Bishopsgate is due for completion later this year.


Farrat’s BBA certificated structural thermal break materials provide building design professionals with a robust solution to minimise energy loss. Suitable to mitigate against planar, linear and point load thermal bridging, Farrat thermal breaks can be used anywhere a penetration or transition exists in a building envelope to help achieve building performance standards. Performance characteristics include low thermal conductivity, high compressive strength and very limited creep under load.

Full specifications are available for import from NBS Plus.

NEW Launch: CineFLOOR Range

CineFLOOR is the new range of acoustic floating floors designed for Cinemas, from Farrat

CineFLOOR is the construction markets first range of high-performance acoustic floating floors designed specifically for cinemas.

The new CineFLOOR range from Farrat offers designers, buyers and clients a ‘simple-to-select’ acoustic isolation solution for auditoriums of all shapes and sizes. From multiplex cinemas to boutique auditorium and private viewing rooms, CineFLOOR acoustic floating floors will keep sound constrained to its source so that you can create truly immersive auditory experiences.

All CineFLOOR systems are designed with ease of installation and follow-on trades in mind. They do not require any ongoing maintenance and will last for the entire lifetime of a building. We are so confident of this that we offer performance warranties up to 25 years – the longest in the industry.

Our engineers have also taken special care to consider build-ability, reliability and robustness in each design to ensure that the operator’s key interests are always upheld.

There are four grades in the range to reflect the most common design variables, ranging from minimum to maximum acoustic isolation performance: NEO, LITE, PRO & MAX.

To identify which CineFLOOR grade of acoustic floating floor is right for your auditorium, use our suitability table:

CINE FLOOR Grade Music Practice Rooms Recording Studios TV Studios Home Cinemas Commercial Cinema 4DX Existing Structures
X Not Often X
X X
Not Often Not Often Check with SE
X X X X Check with SE

To view CineFLOOR key features, technical details and specifications, click here.

CineFLOOR is a Farrat Isolevel Ltd owned brand. © Copyright 2019.

 

Farrat sponsor the Manufacturing Institute’s Make it Enterprise Challenge

The winners trophy for the Cheshire Heat of the Make It Enterprise Challenge

Last Thursday, Farrat was delighted to sponsor and attended the latest round of the The Manufacturing Institute‘s Make It Enterprise Challenge in Knutsford, where 12 schools from across Cheshire took part in a STEM competition to create a hygienic, efficient and profitable food factory. 

The Make It campaign delivered by The Manufacturing Institute, is a STEM initiative aimed at attracting the brightest and best new talent into manufacturing and promoting the sector as an exciting and rewarding career option for young people.

Since 2006, over 30,000 young people and teachers have participated directly in hands-on manufacturing-focused activities that are proven to improve their perceptions of careers in the sector.

In last weeks Cheshire heat, which was sponsored by Farrat and four other North West manufacturers including Air Products, Coveris, Altimex and TATA Chemicals Europe, teams of 13 and 14 year-old boys and girls from local schools were tasked with establishing their own mini-manufacturing businesses in a bid to reach the 2019 Finals.

Students had to design and create a Clean Hygienic Efficient Food Factory for a commercial food manufacturer and complete a series of tasks in specific job roles. Roles ranged from Managing Director to Operations Managers, Finance, Sales and Marketing Managers.

Once their factories were planned, costed and 3D modeled, students then had to develop a sales and marketing strategy and then pitch their fully costed ideas in a Dragons’ Den-style presentation. Help could be gained from Facilitators and Customer Advisers during the day.

The judging panel included Farrat Production Leader Gareth Hogburn.

As a Fellow of The Manufacturing Institute who is trained in the latest LEAN Manufacturing principles & practices, Gareth had a great time quizzing and praising teams on their innovative design choices.

Farrat Production Team Leader Gareth quizzing each team
Farrat Production Team Leader Gareth helping local schools develop their factory ideas
Eleven local schools lined up to win the Cheshire Heat of the MakeIt Enterprise Challenge
Twelve local schools lined up to win the Cheshire heat of the Make It Enterprise Challenge
Farrat proudly sponsored alongside Tata Chemicals, Air Products and Coveris
Farrat proudly sponsored alongside other North West manufacturers
Pointon High School crowned the winners of the Cheshire Heat in the Make It Enterprise Challenge
Poynton High School crowned the winners of the Cheshire Heat in the Make It Enterprise Challenge

All the schools showed great effort, enthusiasm and passion for manufacturing.

After much deliberation, congratulations went to Poynton High School who were crowned winners and took home the trophy of the Chesire Heat. Poynton will now go through to the final next year, to compete against finalists from across the UK.


The Manufacturing Institute –  is an independent charity founded to educate, inspire and improve manufacturing companies and their employees. They deliver a wide range of high quality education, training and consultative services. For more info please visit: www.manufacturinginstitute.co.uk

For more information on STEM events run or facilitated by Farrat, please contact us.

Everyman Altrincham officially opens it’s doors!

The highly-anticipated new Everyman Altrincham opens its doors today following a week of  VIP screenings.

Everyman Cinema Altrincham, acoustically isolated by Farrat

Earlier this year we took our team on a tour of the site during construction following the manufacture of a fully-integrated acoustic isolation system designed for each of the four boutique auditoria. 

It’s not often that Farrat design, manufacture and supply acoustic isolation for a project so close to home, so it was fantastic to get a first-look at the site.

During last nights official launch we took a look around the completed venue.

Everyman Cinema Altrincham - interior
Everyman Cinema Altrincham - bar

Everyman Altrincham public spaces have been divided into a variety of lounge and dining areas. The bar combines luxurious finishes set against exposed brick and steel with views through to a semi open kitchen.

The auditoria corridor leads  from the public space to the 4 auditoria, each of which have their own distinct character. Signature Everyman sofas are upholstered in a variety of velvet finishes and the back drop of walls and floors are clad in rich colours and textures. There is a menu offering a variety of drinks, hot food and snacks which can be consumed in the bar or received via waiter service directly to cinema seats.

Everyman Cinema Altrincham - concession area
Everyman Cinema - Auditorium isolated by Farrat

Acoustic isolation was critical on this project, due to the proximity and function of each of these separate spaces. 

There is an increasing trend for buildings and spaces to have multiple uses, therefore designers must consider disturbing noise and vibration frequencies and their harmonics, to ensure sufficient levels of noise and vibration isolation are achieved.

Using our experience from over 200 cinema projects, Farrat supplied a fully-integrated system to acoustically isolate each auditorium (installed by fit-out contractor G F Holding) –

Specification details for the Farrat systems used in this project are available on NBS Plus.


Everyman Altrincham is a fantastic addition to the Everyman portfolio and certainly a special cinema acoustic isolation project for Farrat.

Farrat gears up to host 450 delegates as ‘Strategic Acoustic Sponsor’ at the MENA Cinema Forum in Dubai

In response to recent research released by PWC that the number of cinema screens in the Middle East are set to jump 38.4% to 1,800 in the next 3-5 years (up from 1,300 currently), the first-ever MENA Cinema Forum will be held this weekend at the Grand Hyatt Hotel in Dubai, October 28-29.

Farrat are Strategic Acoustic Sponsor fo the MENA Cinema Forum in Dubai

The MENA Cinema Forum will be the first ever business conference of its kind for the regional market and will be participated by 45 speakers and experts, 450 delegates and 90 sponsors, including high-performance sound insulation specialists from Farrat, who will act as headline Strategic Acoustic Sponsor.

The conference will offer a detailed research on the current situation and future growth potential of the cinema industry in the Middle East and North Africa (MENA) region, in front of an audience of 450 industry professionals from over 45 counties.

 

Ryan Arbabi, Technical Director of Farrat, and keynote speaker at the MENA Cinema Forum, commented on the decision to put Farrat at the forefront of the conference as Strategic Acoustic Sponsor,  “This is the first event of its kind in the region and  pulls a much wider audience than we’re typically used to speaking to.

“We’re really looking forward to using the event as a great showcase for our new contractor-focused products and services. I’m particularly pleased to be able to use the event to pre-launch CineFLOOR – our new line of Cinema-specific acoustic floating floors.”

 

Leila Masinaei, Managing Director of GM Events, organiser of the MENA Cinema Forum, added that, “The 38.4% additional cinema screens will help the entertainment market to grow faster as additional capacities will be high enough to meet the growing demand that is expected to come from key countries in the MENA region.

“The recent liberalisation and reform initiatives across countries in the MENA region have opened up a lot of opportunities for industry that will see the biggest boom in the entertainment and cinema industry.”

More than US$3.54 billion investment in cinema screens across the Gulf is expected to help the region’s cinema industry expand manifold, following Saudi Arabia’s historic decision to open up the sector 35 years after cinemas were banned in the Kingdom.

 

Oliver Farrell, CEO of Farrat, also commented on Farrat’s commitment to the new Total Acoustic Responsibility service in the MENA region, “In partnership with Sharps Redmore, we’re going to be announcing a brand new initiative exclusive to the MENA region.

“It is unprecedented in its scope and something only world-experts in cinema design such as Farrat and Sharps Redmore could offer, so watch out for a number of exciting announcements from us across the course of the event”.

The eventful conference will be full of activities including workshops, break-out meetings, site visits and major announcements, bringing together the entire spectrum of stakeholders involved within the cinema sector including, but not limited to; local and international governments, investment companies, mall owners, cinema operators and exhibitors, suppliers and industry leaders, to address the growing requirements of the cinema market within the region.

Farrat will be exhibiting at STAND 01 throughout the 2-day conference.

Follow live updates from the event over on our LinkedIn and Twitter pages.

Farrat supply facade thermal breaks for new flagship Adidas store

Farrat thermal breaks used to thermally isolate the facade retention steelwork at new Adidas store

A joint venture between Grosvenor Britain & Ireland and Stow Capital Partners, the 425 Oxford Street retail scheme involves the reconfiguration and extension of the lower five floors of a 10-storey building in the West End shopping district, to create a 45,000 sq. ft flagship unit for Adidas.

The redevelopment features new double-height windows on the ground floor and an extensive glass frontage.

To prevent heat loss through the building facade, Farrat have supplied Structural Thermal Breaks for use within the facade retention steelwork. The facade thermal breaks will act as a thermal insulator and avert thermal or cold bridging.

This is a simple, economical and extremely effective solution to meeting Building Regulations by way of reducing the risk of internal condensation.

Farrat Structural Thermal Breaks can be used in a wide variety of applications where there is a structural requirement of thermal insulation, including:

  • Steel to steel
  • Steel to concrete / masonry
  • Steel to timber
  • Concrete to concrete

 

A full list of typical applications can be found here.


Handover of the bespoke scheme to Adidas is targeted for Spring 2019.

For material properties, design advice and specification details for Farrat Structural Thermal Breaks, please click here.