Project Snapshot
- Client: Ball Beverage Packaging
- Sector: Beverage manufacturing
- Project value: £1.1 million
- Project duration: 12 months
- Operatives on site: Up to 26
- Scope: Mechanical & Electrical installation
- Role on project: Specialist contractor providing skilled labour, plant, project management, and RAMS
- Capabilities provided: In‑house Appointed Persons, supervisors, and M&E‑skilled personnel
Challenge: Replacing a Live Production Line in a Zero‑Tolerance Environment
Ball Beverage Packaging required the removal of a redundant beverage canning line and the installation of a new, state‑of‑the‑art system to support the production of two‑part cans for globally recognised consumer brands. The critical challenge was that the plant needed to maintain full production throughout the works, leaving no margin for disruption, cross‑contamination, or safety compromise.
The project demanded exceptional levels of coordination and control. Works were carried out alongside live manufacturing operations, under strict hygiene and safety requirements, and in close proximity to operational production lines. In parallel, the installation programme had to be delivered to an immovable deadline, with multiple OEMs and stakeholders working concurrently within the same operational footprint.
Adding further complexity, the project included the installation of more than 500 tonnes of new mezzanine and platform steelwork, much of which had to be installed over and around live production areas and seamlessly integrated into existing structures.
Our Solution: Controlled, Collaborative Delivery Around Live Production
We approached the project with a clear focus on planning, people, and partnership. Working under stringent project management controls, our team provided skilled mechanical and electrical labour alongside specialist in‑house plant to safely remove existing equipment and install the new canning line without interrupting production.
Our supervisors and Appointed Persons worked closely with the client, OEMs, and other contractors to sequence works carefully and manage interfaces in real time. By coordinating simultaneous activities across multiple work faces, we ensured that installation, steelwork erection, and equipment integration progressed safely and efficiently.
The steelwork package was delivered alongside machinery installation, with our teams installing extensive mezzanines and platforms in confined environments, often above live lines. This required meticulous planning, constant communication, and absolute trust in the competence of the people delivering the work.
Electrical and mechanical installation works were fully integrated into the programme, supporting the safe commissioning of the new canning line while maintaining the client’s exacting standards for quality, hygiene, and operational continuity.
Specialist Equipment Supporting Safe Installation
Our ability to self‑deliver was key to the project’s success. By using our own specialist lifting equipment and site‑ready plant, we maintained full control over the works and responded quickly to changing conditions on site. This flexibility allowed us to safely manage heavy installation activities within an active manufacturing environment, without reliance on external plant providers.
Expertise Behind the Delivery
At its peak, the project was delivered by a team of up to 26 experienced operatives, supported by in‑house supervisors, Appointed Persons, and project management. Our people were central to navigating the complexities of live production working, bringing practical problem‑solving, strong safety leadership, and the confidence to manage high‑risk activities in sensitive environments.
By combining mechanical and electrical expertise with robust RAMS, disciplined project management, and a collaborative mindset, we delivered the project to the client’s high expectations. This approach has reinforced our position as a preferred contractor, trusted to support multiple clients on complex, high‑stakes manufacturing projects where there truly is no room for error.