Machinery Installation Without Downtime

Keeping abreast of the latest technologies and development is as vital in the packaging sector as it is in any sector. So when a leading packaging manufacturer across over 30 countries identified a specialised packaging production machine, it was to become the “first of its kind” in the UK.

With such a heavy investment, there were inevitable concerns about the installation process, which would require hundreds of separate lifts with some in excess of 22,000 kgs. There were also natural concerns over the ability of the working factory to maintain its high production levels.

Two key decisions, or imperatives, were taken that would have a great impact on the project’s outcome – the first was to commission Flegg Projects to undertake the installation, and the second to keep the plant fully functioning at all times.

Like in any business, any downtime in production would affect the bottom line. A challenge indeed but for Flegg Projects, with their experience of relocating and installing heavy machinery, the project was ‘business as usual’ in some respects. Every project is, of course, different and Flegg treats them as unique but common to all installation projects is the need for informed planning, superb project management, clear communications and adequate resource. This installation was a complex undertaking, as the factory had to remain fully operational, and it involved several onsite contractors, across a range of disciplines.

The project was successfully delivered in phases over a duration of six months. Constant communication was needed between Flegg’s project management team and the client’s in-house team to ensure that working patterns and key timeline targets set out in the plan were achieved.

Flegg Projects used their expertise and knowledge to offload and unpack equipment from third-party vehicles and provide engineering support to the machine supplier to assist with the mechanical assembly. The selection of moving and lifting equipment required included versalifts, vehicle-mounted cranes, counterbalance forklifts and MEWPS – all provided from their own well-maintained fleet. Having invested heavily over the past few years in all of the equipment they use regularly, Flegg Projects are sure that it’s in top condition and fully operational at all times. With critical timings, projects such as this packaging installation cannot be let down by equipment.

The result – a safe installation and factory productivity levels were maintained. The client was delighted with Flegg Projects’ performance and with their new machine, which has been contributing to their business, churning out product 24/7.

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View article in the Food & Drink Processing & Packaging digital online magazine.