Project Overview

Our management team led the complete relocation and recommissioning of a full high-speed beverage production line for a major global beverage manufacturer — one of the most recognised brands in the world. Delivered under the direct leadership of Jonathan Molloy as principal project lead, the project covered every phase from initial survey and layout planning through full mechanical and electrical dismantling, transport, reinstallation, multi-OEM commissioning and live performance ramp-up.

This was not a machinery move. It was a complete line redesign, rebuild and recommissioning in a new factory environment — managing multiple contractors, OEM specialists, structural works, utilities, controls integration and commercial pressures simultaneously, and driving the line back to its previous production efficiency target.

Project Scale

Client Major global beverage manufacturer

Project type Full production line relocation, redesign, line upgrade procurment, reinstallation & recommissioning

EquipmentKrones, KHS, Logopack, Robopac — high-speed PET beverage line

Scope Survey → Dismantle → Transport → Reinstall → Commission → Performance ramp-up

Role Single point of accountability across all disciplines

Outcome Line returned to previous production efficiency target 78% OEE

Scope Delivered

Pre-Project Planning & Survey Full site assessment of the existing production line. Asset identification, condition checks, dismantling requirements, transport and access planning, layout feasibility for the receiving site, critical path risk identification and full coordination with client engineering, operations, EHS and project teams.

Line Redesign & Layout Coordination Development of new production line layout for the receiving factory. Coordination of 3D drawings and 2D layouts against real site constraints including drainage, structural steel, pipe bridges, office access, cable routes and equipment interfaces. Management of conveyor modifications, shortened sections and equipment interface changes to reduce unnecessary modification costs.

Structural & Access Modifications Mezzanine design and fabrication coordination, platform modifications, access stair changes, steelwork and support coordination, cable tray support redesign due to roof loading restrictions.

Mechanical & Electrical Dismantling Full mechanical dismantling of process and packaging equipment. Electrical disconnection and de-cabling. Specialist asset tagging and match marking of all machines, cables, panels and components to support accurate reassembly. Site clearance and preparation for loading.

Packaging, Transport & Logistics Seaworthy packaging strategy for sensitive and hygienic components. Load sequencing aligned to installation programme. Transport coordination, site access planning and offloading at receiving site.

Mechanical Installation & Utilities Full reinstallation of process and packaging equipment. Conveyor installation and modification. Pipework installation covering compressed air, water, drainage, CIP and process utilities. Replacement of stainless pipework where existing infrastructure was not fit for purpose.

Electrical, Controls & Safety Cable tray route design, supply and installation. Panel integration, I/O testing, signal verification, safety circuit integration, emergency stop and guarding validation. Support for PLC and software commissioning issues.

OEM Coordination & Commissioning Managed and coordinated multiple OEM and specialist teams including Krones, KHS, Logopack, Robopac and conveyor system suppliers — covering quotation management, attendance coordination, commissioning window alignment and commercial dispute resolution. Delivered staged commissioning from dry checks through wet commissioning to live production.

Performance Ramp-Up & Commercial Management Performance troubleshooting across filler, blower, conveyors and packaging systems. Snag list management, acceptance test planning and ongoing optimisation. Commercial management of multiple subcontractor scopes, variation negotiation, KHS commissioning cost dispute resolution and cashflow management across an extended programme.

Capability Demonstrated

This project is the benchmark for what Vertex delivers at the highest level of industrial project complexity — main contractor responsibility across engineering, logistics, utilities, controls, OEM management, commercial negotiation and live performance recovery. A single point of accountability from survey to production restart, on one of the world's most demanding manufacturing clients driving the line back to its previous production efficiency back to 78% production efficiency — matching the line's proven performance from its previous factory