Overview
ForFarmers UK Ltd, a division of ForFarmers Europe, operates one of its key facilities at Exeter Mill, producing over 190,000 tonnes of animal feed annually. In September 2024, the site experienced a catastrophic electrical failure due to a transformer fault, threatening to halt production entirely. To restore operations and modernise the aging infrastructure, ForFarmers partnered with Pleavin Power to deliver disaster recovery and a full substation rebuild.
Challenges
A direct short in Transformer TX1 caused critical switchgear to fail, cutting off power to the entire mill. With a daily output of up to 700 tonnes, downtime posed a significant operational and financial risk. The site’s electrical infrastructure dated back to the 1970s, further complicating the response. The challenge required not only full disaster recovery and power restoration but also a long-term upgrade to ensure future resilience.
Solutions
Following a critical power failure, Pleavin Power responded within hours—arriving on-site by 5:30 AM and restoring full power by 8:00 PM the same day. Emergency power was swiftly established using mobile switchgear and generators, monitored via telemetry, with daily fuel logistics coordinated to ensure continuous operation.
After stabilising the site, the team carried out a detailed inspection of the substation. Due to the dated infrastructure and a failure in the TX1 transformer and associated switchgear, they recommended a complete substation rebuild. This required complex planning, which involved the safe removal of asbestos, installation of modern switchgear and full refurbishment of both the low-voltage (LV) and high-voltage (HV) systems.
The project was expertly managed by Jack Pleavin, Chris Lloyd and Chris Woosey, with on-site engineering works delivered by Andy and George.
Pleavin Power continues to provide ongoing support to ensure the long-term resilience and reliability of ForFarmers’ power infrastructure.
Benefits
Minimised Downtime
Modernised Electrical Infrastructure
24/7 Monitoring & Fuel Management
Improved Safety & Compliance
Future-Proofed Operations
Increased Organisational Confidence
“The quality of service provided by Pleavin Group was exceptional to say the least. The customer support, reassurance and confidence that they were in control of our disaster was very, very impressive.”
— Mike Simcox, Engineering Manager, ForFarmers Exeter Mill.
