Introduction

Forgery presents serious risks not only to companies but also to the wider economy, making the development of a distinctive security feature essential for one of the world’s most recognizable electroplated coins. To be effective, the solution had to be inherently linked to the electroplating process and extremely difficult to replicate. Drawing on my extensive background in Industrial Process Engineering—alongside robust leadership abilities and formal training in world-class project management methodologies—I successfully delivered innovative, compliant solutions that fulfilled these demanding criteria while upholding engineering best practices throughout.

Challenges
A promising product emerged that could potentially be integrated into the electroplating process, though it had never been trialled in this context before—demanding truly “out-of-the-box” thinking. Given the incorporation of potentially hazardous procedures within an Upper Tier COMAH site, the design phase required a meticulous engineering compliance review to ensure safety and regulatory alignment. The complexity and originality of the concept posed such significant challenges that it proved difficult to find any global partners willing to take on a project of this scale and ambition.

Approach

To drive success in this highly specialised project, it was crucial to identify a knowledgeable design partner with deep expertise in industrial process equipment. The strategy centred on deploying robust methodologies such as Hazard Studies, LOPA, Risk Assessments, and comprehensive Engineering Compliance Reviews to ensure technical integrity and regulatory alignment. Strong, client-focused project and program management were demonstrated through effective leadership, fostering clear communication and accountability. Extensive prototyping trials were conducted to determine the most effective solution, while project management best practices were rigorously applied to maintain control over quality, budget, and schedule.

Results and Conclusions

Through detailed prototyping, rigorous testing, and careful design evaluation, a skid-mounted, bolt-on equipment module was developed to integrate the security feature directly into the electrolyte, enhancing overall product integrity. Designed for interchangeable processes, the system enabled a seamless transition between the traditional electroplating method and the newly introduced security-enhanced procedure—resulting in a highly sustainable solution. Delivered with a strong commitment to operational excellence, compliance management, and design optimisation, the plant met all business case objectives and demonstrated a clear ability to solve complex process challenges. Leveraging robust design strategies, it gained approval for deployment on an upper-tier COMAH site and operated safely for over a decade without any significant incidents or operational losses