Latest success story: Packing line upgrade and installation

The program aimed to initiate a major production modernization through the replacement of existing manufacturing lines with advanced production systems, significantly improving operational efficiency while reducing packaging raw material consumption.

The project was delivered in five phases:

1. Removal of the existing equipment

2. Modification and relocation of utilities to meet the requirements of the new production line

3. Building modifications to accommodate the new equipment

4. Installation and commissioning of the new production line

5. Optimization of the new line to achieve target performance

Execution and challenges

• Working next to active production

Construction activities took place inside an operating factory. To ensure uninterrupted production and maintain product quality, the project team implemented specialized dust containment systems, established controlled work zones, and executed detailed planning and coordination throughout every stage of the project.

• Moving large equipment

Several machines had to be removed and installed through restricted areas. Multiple route studies and simulations were made before selecting the safest and most efficient access path. Advanced moving equipment such as industrial lifting platforms were used to navigate heavy equipment in tight corners.

• Structural modifications for new access routes

New access routes were created to accommodate the installation of the production line, requiring new wall openings and structural reinforcements. Comprehensive structural assessments and safety approvals were completed before construction commenced ensuring the integrity of the facility and the safe execution of all modification works.

• Tight shutdown windows

Critical utilities and installation activities had to be completed within short shutdown periods. Careful planning and coordination allowed the work to be completed while keeping the project on schedule.

• Installation adjustments

Differences between the existing site conditions and the original drawings created alignment and interface challenges with the existing equipment.

Key Results

• Project delivered on schedule and within budget

• Over 5,000 safe working hours achieved

• Zero safety incidents

• No interruption to factory production

• New packaging equipment successfully installed and commissioned