Case Study: Engineering a Seamless Factory Relocation Across Borders
Key Electrical Scope Highlights
- Design, supply, and installation of full LV electrical containment systems, including tray, ladder, and basket
- Installation, termination, and testing of mains power, control, and data cabling
- Full panel installation, interfacing, and commissioning support for a complete production line
Project Snapshot
· Project name: Project Eagle
· Client: Filtrox
· Locations: Switzerland (removal) and Barnoldswick, UK (relocation)
· Project duration: April 2024 – January 2025
· Role on project: Principal Contractor
· CDM responsibility: Yes
The Challenge: Delivering a Complex International Factory Relocation
We were appointed by Filtrox to deliver the full disconnection, relocation, and reinstallation of a complete production facility, relocating the factory from Switzerland to a new site in Barnoldswick. The scope covered the full production process, including pulp handling and preparation, filter forming and processing, drying and finishing stages, automated handling and transfer systems, and packing and end‑of‑line operations.
Working internationally introduced additional layers of complexity, including language barriers, regulatory differences, and the logistical challenges associated with transporting large, heavy plant across borders. Many of the production assets involved significant weights, requiring careful planning and specialist lifting expertise at every stage of the move.
At the new location, the challenges shifted again. Space was extremely restricted, creating tight working areas for both installation and logistics management. Heavy equipment had to be maneuvered into position with limited access while maintaining programme certainty and safety compliance. Alongside this, we were responsible not only for mechanical relocation but also for delivering extensive new electrical works to support the reinstated production line.
Our Solution: End‑to‑End Control Across Mechanical and Electrical Delivery
As Principal Contractor and CDM duty holder, we took full responsibility for coordinating the relocation from initial disconnection in Switzerland through to final commissioning in the UK. Our integrated approach ensured mechanical, electrical, and lifting activities were carefully sequenced to reduce risk and maintain control across multiple locations.
Mechanical disconnection works were carried out methodically, with all machinery match‑marked, protected, and prepared for transport to ensure accurate reinstallation. On arrival at the Barnoldswick facility, we managed the reinstatement of the full production line within a constrained footprint, carefully planning logistics and lift sequences to maximise space efficiency and maintain safe working zones.
In parallel, we delivered comprehensive electrical works for the new factory. This included the design, supply, installation, termination, and testing of all electrical containment, mains distribution, control systems, and data infrastructure required to support a high‑reliability manufacturing process. All works were carried out within a live industrial environment, requiring close coordination with mechanical installation teams and strict adherence to safety, quality, and programme requirements.
Electrical Delivery: Supporting a Full Production Line
Our electrical scope covered the complete infrastructure required to support the relocated production line, from incoming power through to final control and communications systems.
Electrical containment systems were installed throughout the facility, including overhead tray, ladder, and basket routes suspended from structural steel and soffits. Vertical and horizontal routes were carefully coordinated to segregate power, control, and data services while avoiding clashes with ductwork, pipework, tanks, and process equipment. The result was a clear, accessible installation that allows for future maintenance and expansion.
Mains power distribution was installed from LV supply points to local and main distribution panels, with power cabling routed to motors, drives, heaters, and process equipment. All cabling was neatly dressed, gland‑terminated, and clearly labelled in line with drawings and commissioning requirements. Panels and local distribution points were installed adjacent to process equipment, with structured internal wiring and clear segregation of power and control circuits.
Control, instrumentation, and data cabling were installed across the production line, connecting PLCs, MCCs, sensors, actuators, valves, and HMI systems. All terminations were completed in accordance with relevant standards, followed by full testing including continuity, insulation resistance, polarity checks, and point‑to‑point verification. Our team supported commissioning activities during energisation and functional testing, ensuring the installation was ready for production.
Safety, Compliance, and Heavy‑Lift Risk Management
Safety was critical throughout the project, particularly during heavy lifting operations. One of the most complex stages involved lifting large plant onto a mezzanine floor using a jacking system. When it became clear that the floor had not been adequately designed by external stakeholders to support the imposed loads, we worked proactively to have the structure properly braced, ensuring stability and compliance before lifts proceeded.
Specialist plant and equipment – including jacking systems, cranes, 7‑tonne forklifts, and 11‑tonne Valla cranes – were selected to suit the restricted access and weight requirements at each stage of the works. As CDM duty holder, we ensured all activities were fully risk‑assessed, planned, and executed in line with safety regulations.
Expertise Behind the Delivery
The successful delivery of Project Eagle relied on the combined expertise of our mechanical, electrical, and lifting teams, supported by experienced Appointed Persons and project leadership from our Wigan branch. By managing both mechanical relocation and full electrical installation in‑house, we maintained consistent standards, clear communication, and full accountability throughout the project lifecycle.
Working closely with designers, the client, and other contractors, we adopted a collaborative, problem‑solving approach to overcome design gaps, space constraints, and programme pressures, ensuring the project was completed safely and to timescale.
Going the Extra Mile and Building Long‑Term Value
Throughout the project, we worked flexibly with Filtrox and the wider project team to resolve challenges and keep works progressing, even where this required adapting plans or responding to unforeseen issues. This approach strengthened relationships and reinforced trust.
As a direct result of the delivery on Project Eagle, we have subsequently secured nine additional projects, demonstrating the lasting value of a people‑led, solutions‑focused approach to a complex pan-European factory relocation and installation works.