Molan UK Ltd operates from a large site in Heckington, Lincolnshire, combining offices, production areas, manufacturing spaces, storage facilities and large warehouses.

A one-size-fits-all approach to fire detection would not have worked here. Each part of the site carried different risks, from high ambient noise and airborne micro-dust to moving forklifts, high-level warehouse space and a manufacturing operation that runs continuously.

Following a fire risk assessment by Arion, RJ Wilson Fire & Security was brought in to design and install a practical fire detection and alarm system, tailored to the individual risks across the site.

The Challenge

The objective was simple: detect a fire effectively, warn everyone on site clearly, and support a safe evacuation from every area. Achieving it was less simple, because the site’s two large buildings contained very different working environments.

• Offices needed suitable automatic smoke and heat detection, together with alarm warning devices.
• Warehouse and storage areas featured large open spaces, varying ceiling heights, forklift traffic and obstructions that change as stock moves.
• Manufacturing areas included processes and airborne particles, including micro-dust, that made conventional smoke detection unsuitable in places.
• Noisy areas with significant, continuous background noise meant the alarm strategy had to ensure staff could still be warned effectively.
• One high-level area with a ceiling height of more than 10.5 metres, where conventional point smoke or heat detectors were not the right solution. Beam detection was selected instead.

Just as important, Molan had to stay fully operational throughout the installation. A prolonged production shutdown was not an option.

A Risk-Led Approach

From the outset, RJ Wilson Fire & Security worked closely with Molan and Arion to understand how each area was used, the risks involved and the client’s practical requirements.

Rather than apply a single detection philosophy across the whole site, the design was divided into individual areas, each assessed on its own risk. The result was a combination of automatic detection and manual call point coverage, aligned with the principles of BS 5839-1 and the findings of the fire risk assessment. Different areas reflect L1, L3 and M principles (broadly, automatic detection throughout, detection focused on escape routes, and manual call points only), with the final strategy agreed with Arion.

This approach put protection where it was needed without over-engineering areas where extra automatic detection would add little benefit, keeping the solution commercially realistic and within the client’s budget.

The Solution

RJ Wilson Fire & Security designed and installed a Honeywell SMS fire detection and alarm system across the site, configured around the needs of each environment.

Office areas

A combination of smoke detection, heat detection, manual call points and alarm warning devices suited to how each space is used.

Warehouse and storage areas

Automatic smoke detection was installed in the appropriate warehouse areas. Other open storage areas were protected with manual call points where the fire risk assessment found this to be suitable. The design also accounted for forklift movements and obstructions created by stored goods.

Manufacturing areas

Heat detection was chosen where it offered a more suitable and reliable option than smoke detection. This reduces the potential for unwanted alarms while still providing protection proportionate to the risks identified.

High-level areas

With ceilings above 10.5 metres, beam detection provides effective coverage across the large open space without relying solely on point detectors at height.

Alarm warning

Detecting a fire is only half the job; people have to hear the warning. Areas with high background noise were considered as part of the detection design, rather than as a separate afterthought, so that employees across the premises can be warned effectively and evacuate safely.

Installing Around a Live Operation

A major part of the project was planning the installation around Molan’s day-to-day operations. The site stayed operational throughout, so works were coordinated closely with the client.

Different working patterns and shift arrangements were used in different areas, allowing our engineers to carry out the installation without unnecessary disruption to manufacturing. Specialist access equipment was used to complete work safely in the warehouse and high-level areas.

The project was completed without Molan having to shut down production, improving life safety without a significant commercial impact on the business.

Testing and Handover

After installation, the system was tested and put through a soak period before final handover. It completed the soak test successfully, confirming that the mix of detection technologies chosen for each environment was right for the site.

Molan now has one coordinated fire alarm system, with each area still protected according to its own specific risks.

“We were really impressed by how smoothly the installation was completed, with very little disruption to our day-to-day operation. The engineers were friendly and professional, the quality of the installation is excellent, and we have complete confidence in the finished system.”

Molan UK Ltd

Remote Monitoring and Ongoing Support

The project did not end at handover. Remote fire alarm monitoring was connected, adding a further layer of protection by transmitting alarm signals off-site.

RJ Wilson Fire & Security was subsequently awarded the ongoing fire alarm maintenance and monitoring contract, so the system continues to be supported by the same team that designed, installed and commissioned it. That relationship also means the system can be reviewed as Molan’s operations, processes or building layouts change.

The Result

Molan now has a fire detection and alarm system designed around the way its business actually operates. Instead of a standard solution applied to a complex site, several detection methods and levels of protection were combined to suit each environment.

• A bespoke Honeywell SMS system serving a complex, multi-area site
• A risk-led design developed with Molan and Arion, aligned with the fire risk assessment and the principles of BS 5839-1
• Different detection strategies for offices, warehouses, manufacturing areas and high-level spaces
• Beam detection in the high-level warehouse area
• Dust, background noise, forklift movements and changing stock layouts all taken into account
• Installation completed around a fully operational site, with no planned production shutdown
• A successful testing and soak period
• Remote monitoring connected, with ongoing maintenance and monitoring provided by RJ Wilson Fire & Security

Designed Around the Customer

The Molan project shows the value of combining fire risk assessment, specialist fire alarm design and practical installation experience. Complex commercial and industrial sites rarely suit a standard approach.

By working with the client and the fire risk assessor, we assessed the risks in each area, selected suitable detection technology, and delivered a system that balances life safety, operational needs and budget. The result is not just a new fire alarm, but a solution built around the customer’s premises, people and working environment.

Need fire detection that suits your site?

Talk to RJ Wilson Fire & Security about fire alarm design, installation, maintenance and monitoring for your premises. Call 01522 427 113 or request a free quote.