01
Civil Construction Solutions
Project background
Mission:
As the company's operational needs evolved, heavy machinery was introduced on the first level of a factory to support increased production demands. The additional load required a structural retrofitting of the building to ensure safety, stability, and compliance with engineering standards.
Design and implementation:
The project was executed using Integrated project delivery method and with good collaboration with UK construction company and designer the project was delivered in time and within budget.
Execution & Challenges:
The reinforcement of columns was carried out on top of the pallet racking, presenting a significant safety challenge for working at height. To mitigate this risk, a collective protection system was implemented, incorporating a complex scaffolding structure to ensure worker safety.
Additionally, the project was executed during the COVID-19 pandemic, introducing further challenges related to health and safety protocols, workforce availability, and schedule management. To address these challenges strict HS&E protocols were implemented, shift work to minimize exposure and close coordination with suppliers to prevent material shortages.
2500 sqm
Of reinforced concrete flooring completed
40
Columns and beams reinforcement completed, supported by 800sqm of scaffolding
0
Impact to ongoing operations
Project
Structural reinforcement
Location
London, UK
Investment
Mid-sized project
02
Greenfield Projects
Project background
Mission:
Due to insufficient capacity in the existing facility, a new office and administrative building was required to accommodate staff, lockers, and operational teams. The goal was to provide a permanent, fully equipped workspace while meeting all regulatory requirements.
Design and implementation:
-
A modular construction approach was chosen to ensure a fast and efficient build.
-
The building was fully connected to utilities and designed to meet long-term operational needs.
-
Special permits and authorizations were obtained to comply with regulatory standards.
Execution & Challenges:
Time-sensitive project: A fast-track schedule was developed to ensure staff relocation occurred on time.
Coordination & logistics: Careful planning was required to integrate utilities and finalize the structure without disrupting existing operations.
1,000 sqm
Fully equipped office building delivered
3
Months execution to meet the strict schedule.
Thermally efficient structure, ensuring sustainability and cost savings in energy consumption.
Project
Modular Construction Building
Location
Germany
Investment
Mid-sized project
03
Logistics Automation Technologies
Project background
Mission:
A traditionally manual warehouse was transformed into a fully automated pallet handling system to improve speed, efficiency, and cost-effectiveness. The goal was to reduce manual labor, optimize material flow, and enhance overall warehouse performance.
Design and implementation:
To achieve full automation Automated Guided Vehicles (AGVs) were designed and installed. These AGVs were programmed to handle pallet operations faster, more efficiently, and at a lower cost compared to manual processes. The system was integrated seamlessly to ensure smooth operations with minimal disruption.
Execution & Challenges:
✅ Modifications to the existing building were necessary to create the best possible routes for the AGVs, ensuring smooth navigation and optimized workflow.
✅ Calibrating the AGVs to work with various pickup and drop-off levels required precise adjustments. This challenge was addressed through intensive testing on a single AGV, ensuring accurate performance before applying the settings to the entire fleet
20 AGVs
Successfully installed to optimize pallet handling.
Significant reduction in labor costs by minimizing manual intervention. · Enhanced operational efficiency, leading to faster and more reliable warehouse performance
Project
AGV Fleet Implementation
Location
Germany
Investment
Mid-sized project
03.1
Logistics Automation Technologies
Project background
Mission:
An increase in storage and retrieval capacity was needed in the existing Automated Storage and Retrieval System (ASRS). The goal was to expand storage and transportation capacity both vertically and horizontally while keeping operations running smoothly.
Design and implementation:
To handle the extra volume, 12 new ASRS machines were installed. A low-bay conveyor system was added to move pallets between the machines efficiently. The design made sure the system could handle the increased load without delays or disruptions.
Execution & Challenges:
The project involved several challenges:
✅ Working at heights over 20 meters, which required strict safety measures to prevent falls.
✅ Moving vehicles in the warehouse, making it necessary to set clear safety zones and ensure workers used protective equipment.
✅ Lifting and installing heavy parts, which was safely done using high-capacity electric hoists.
By following detailed planning, strict safety rules, and careful execution, the warehouse upgrade was successfully completed. This resulted in higher storage capacity with improved efficiency.
30%
Increase in ASRS storage and retrieval capacity, optimizing warehouse operations.
12
New ASRS machines installed, enhancing material handling efficiency.
0
Operational disruptions during installation ensuring continuous workflow.
Project
ASRS Capacity increase
Location
France
Investment
Large scale - project
04
Production and Pallet Handling Equipment
Project background
Mission:
Our client needed to increase their production capacity and improve how pallets moved from production lines to storage. To achieve this, they required a well-planned system that could handle higher pallet volumes efficiently without disrupting operations.
Design & Implementation:
An advanced pallet handling system incorporating a network of conveyors and pallet elevators was designed. This system automatically picked up pallets from different areas, stacked them, and transported them quickly to their destination using a fast-track lane. The goal was to reduce manual work, speed up logistics, and improve overall efficiency.
Execution & Challenges::
Since production had to continue during installation, we carefully planned the project in phases. The system was integrated step by step to avoid downtime and ensure smooth operations. By managing the project with precision, we successfully delivered a reliable and high-performance pallet transport system that boosted productivity and optimized workflow.
9000 sqm
Conveyor system installed
40%
Improvement in throughput efficiency
80,000
Safe working hours with zero Safety incidents
Project
Pallet Conveying System Upgrade
Location
France
Investment
Large-sized project
04.1
Production and Case packing
Project background
Mission:
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.
Project delivery in five phases
- Removal of the existing equipment.
- Modification and relocation of utilities to meet the requirements of the new production line.
- Building modifications to accommodate the new equipment.
- Installation and commissioning of the new production line.
- Optimization of the new line to achieve target performance.
Detailed planning, equipment movement simulations, engineering reviews and dust containment systems were used to ensure a safe execution inside an active manufacturing environment.
Execution & 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 robot lifting platforms were used to navigate heavy equipment in tight corns within the manufactory.
9000 sqm
Conveyor system installed
40%
Improvement in throughput efficiency
80,000
Safe working hours with zero Safety incidents
Project
New manufacturing and packing lines
Location
Germany
Investment