Project Overview
Airmatic Ltd was engaged by Anel Engineering & Contracting to support the major Shotton Paper Project, delivering a large‑scale package of high‑integrity ductwork systems and associated structural supports for a complex industrial process environment.
The project involved the manufacture of multiple ducting systems across a range of materials, including 316 and 304 stainless steel, mild steel and galvanised steel. Working across several process areas within the facility, Airmatic provided a fully fabrication‑led solution designed to meet demanding operating conditions while maintaining consistent engineering standards throughout.
With a total project value exceeding £1.18 million, the contract demonstrated Airmatic’s capability to manage large‑scale industrial manufacturing packages while delivering the precision, flexibility and reliability required for critical process applications.
Scope of Work
The scope covered the manufacture of high‑integrity stainless‑steel process ducting systems, mild steel and galvanised ductwork with a comprehensive package of bespoke structural supports.
Working from client‑issued engineering drawings, Airmatic translated complex design information into manufacturable fabrication packages suitable for efficient production and installation across multiple process zones.
1. Stainless Steel Process Ducting
Airmatic manufactured a comprehensive range of 316 and 304 stainless‑steel ducting systems designed for demanding industrial operating environments.
The fabrication package covered multiple process areas including:
All stainless‑steel ductwork was manufactured to high‑integrity standards, ensuring durability, reliability and long‑term performance within process‑critical applications.
2. Mild Steel & Galvanised Ducting Systems
In addition to stainless systems, Airmatic manufactured black steel and galvanised ductwork incorporating both rectangular and round duct sections.
The systems formed part of integrated heat recovery and drying processes, requiring robust fabrication methods and careful material selection. Exposed steelwork received protective zinc coatings to provide additional corrosion resistance and long‑term protection in industrial operating conditions.
3. Ducting Supports Package
Alongside the ductwork systems, Airmatic produced a bespoke package of stainless‑steel ducting supports fabricated across multiple drawing references.
The supports were manufactured from 316 and 304 stainless steel using high‑integrity welding processes to ensure structural strength, dimensional accuracy and compatibility with the wider ducting systems.
Engineering & Manufacturing Approach
The Shotton Paper Project was delivered through Airmatic’s in‑house fabrication facilities in Bury, where rigorous internal engineering standards and quality procedures were applied throughout production.
A range of advanced fabrication and welding techniques were utilised, including:
To ensure system integrity and long‑term reliability, all ducting systems incorporated:
Surface Treatment & Quality Assurance
As part of the finishing process, all stainless‑steel systems underwent acid pickling and passivation treatment to improve corrosion resistance and surface finish quality.
Although no formal manufacturing specification was provided, Airmatic applied its own internal QA procedures, engineering expertise and industry best practice standards to ensure consistent fabrication quality across all systems.
Commercial & Delivery Model
The project was delivered on an Ex‑Works supply basis, with optional logistics support available to meet project requirements.
Given the scale and complexity of the package, the project was managed through a structured commercial model featuring milestone‑based payments aligned with the production programme. This flexible approach enabled efficient project management while supporting changing manufacturing and delivery demands throughout the contract.
Technical hurdles we faced and the solutions we provided:
Absence of Formal Manufacturing Specifications: The lack of a detailed manufacturing specification required Airmatic to apply internal engineering standards, fabrication expertise and practical judgement throughout the production process.
Large Multi‑System Scope: The project involved the coordination of numerous drawing packages and process systems across multiple operational areas, requiring careful planning and production management.
Material Diversity: The integration of stainless steel, mild steel and galvanised systems within one manufacturing package required consistent quality control procedures and adaptable fabrication methods.
High‑Integrity Requirements: The ducting systems were designed for process‑critical environments where reliability, sealing integrity and long‑term durability were essential.
The solution and what we delivered:
Airmatic delivered a fully engineered and fabrication‑led solution tailored to the demands of the Shotton Paper Project.
This included:
By combining engineering expertise with in‑house manufacturing capability, Airmatic ensured efficient project delivery while maintaining the high standards required for industrial process applications.
What long-term benefits can the client see:
The completed project successfully delivered a comprehensive ducting and support package valued at more than £1.18 million.
Airmatic’s involvement provided the client with a dependable manufacturing partner capable of managing multiple material types, large fabrication volumes and demanding engineering requirements within a single coordinated package.
The project demonstrated:
Conclusion
The successful delivery of the Shotton Paper Project highlights Airmatic’s ability to manage complex, large‑scale industrial ductwork packages across multiple materials, systems and process areas. From stainless steel process ducting through to mild steel, galvanised systems and bespoke structural supports, the project demonstrated the strength of Airmatic’s in‑house manufacturing capabilities, engineering expertise and commitment to quality at every stage, providing a reliable and efficient solution tailored to the demanding requirements of a major industrial facility.
The project further reinforces Airmatic’s reputation as a trusted manufacturing partner for large industrial and process‑critical applications, capable of delivering technically demanding ductwork systems with precision, reliability and scalability. Through a combination of skilled engineering, advanced fabrication techniques and responsive project delivery, Airmatic continues to support major infrastructure and manufacturing projects throughout the UK.