Production Line Relocation – Global Leading Beverage Manufacturer
We led the full relocation of a high-speed beverage production line from one facility to another, taking responsibility from dismantle through to restart and performance ramp-up. The project involved moving a complete system into a new environment, upgrading elements of the line, and bringing it back into production under real operating conditions.
Scope delivered:
- Development of new line layout
- Creation of 3D drawings and installation plans to support build and coordination
- Identification and procurement of new equipment to upgrade and improve line performance
- Full mechanical and electrical dismantling of process and packaging equipment
- Asset tagging, documentation, and controlled strip-down to preserve settings and alignment
- Packaging and protection of hygienic and sensitive components for transport
- Load planning, lifting studies and permits, and transport sequencing aligned to installation programme
- Coordination of logistics, deliveries, and site access constraints
- Reinstallation of full production line including process equipment, conveyors, and packaging systems
- Alignment, levelling, and anchoring of all major equipment and line infrastructure
- Installation of utilities including compressed air, water, drainage, and CIP systems
- Full pipework installation and modification to suit new layout and process requirements
- Installation and modification of cable tray routes and electrical infrastructure
- Fabrication and installation of mezzanine and structural steel to support new layout
- Electrical and controls reinstatement including panels, field devices, and network integration
- Fault finding and correction of issues introduced during relocation and reinstallation
- Safety system validation including guarding, interlocks, and emergency stops
- Management and coordination of OEMs and specialist contractors across all disciplines
- Oversight of commissioning activities with OEMs including Krones, KHS, Logopac, Robopac, and conveyor system suppliers
- Coordination between engineering, operations, and site teams in a live production environment
- Delivery of staged commissioning from dry checks through to wet commissioning and live production
- Performance troubleshooting across filler, blower, conveyors, and packaging systems
- Ongoing optimisation to stabilise output and improve line efficiency under real operating conditions
- Rapid response to production-critical issues, maintaining momentum and minimising downtime
- Driving the line from installation through to operational readiness and performance ramp-up
Project delivered under Jonathan Molloy’s leadership as principal project lead.