Key Facts:
- Dismantling of production lines
- Transportation of machinery
- Reinstallation and Commissioning
- Versa-Lifts and JMGs
- Valla cranes
- Completed within 6 Months
Project Pegasus – Packaging Manufacturer
Client overview Ball Aerosol Packaging, a global leader in sustainable aluminium packaging solutions, has a rich history of innovation and environmental responsibility. They’ve served markets worldwide for over 140 years, supplying high-quality products for personal care, home care, and industrial applications. Their dedication to operational efficiency and environmental sustainability has positioned them as a key player in their sector. Project Pegasus: The challenge To enhance their operations at the Ball Aerosol facility in Devizes, Wiltshire, Ball Aerosol Packaging embarked on Project Pegasus, a comprehensive upgrade involving the relocation and reinstallation of production lines 56 and 57. The goal was to relocate these critical lines into a newly constructed facility while ensuring minimal downtime, seamless integration, and adherence to safety standards. Given the complexity of this project, Ball Aerosol Packaging required a trusted partner with extensive expertise in industrial relocation, heavy machinery installation, and compliance with stringent safety and operational protocols. As such, VIG Industrial Relocation was appointed to handle this challenging task. What we needed to do Comprehensive project scope The project, valued at £1.25 million, would need to be completed in six months, from planning through to commissioning. VIG was responsible for:
- Dismantling production lines: Including the disconnection of mechanical and electrical components.
- Transporting machinery: Using specialist lifting equipment to ensure safe handling of sensitive and heavy machinery.
- Reinstallation and commissioning: At the newly constructed facility, ensuring seamless operation post-move.
What we delivered
Dynamic project management We assumed the key role of Principal Contractor to oversee safety and compliance across the site, always adhering to the Construction Design and Management of 2015 regulations. The project required meticulous planning and adaptability due to challenges like delayed machinery arrivals from suppliers. VIG’s team worked dynamically, adjusting schedules and coordinating multiple subcontractors to ensure the project stayed on track. Skills and expertise We deployed a skilled team comprising of:
- Riggers for precise equipment handling
- Mechanical engineers for dismantling, reassembling, and commissioning the machinery
- Electrical engineers to ensure all connections were safely and efficiently integrated
This multidisciplinary approach allowed for efficient problem-solving and flexibility throughout the project, ensuring every aspect of the relocation met Ball Aerosol Packaging’s requirements. Specialist equipment To manage the complex relocation and installation processes, we utilised an array of advanced machinery, including:
- Forklift trucks for agile and precise movement of smaller components
- Versa-Lifts and JMGs for heavy lifting and transport in tight spaces
- Valla cranes for high-precision placement of equipment
- Cranes for large-scale hoisting operations
Results and key achievements
Seamless transition: Despite logistical challenges, VIG successfully delivered the project within the specified six-month timeline, ensuring the production lines were fully operational in the new facility by the agreed deadline. Enhanced efficiency: By handling every aspect of the project, from mechanical and electrical disconnections to final commissioning, we ensured a streamlined relocation process that minimised downtime and disruption to Ball Aerosol Packaging’s operations. Commitment to safety: Zero notifiable incidents were reported, thanks to VIG’s rigorous risk assessments, safety protocols, and dynamic planning processes. Why choose VIG Industrial Relocation? Project Pegasus exemplifies VIG’s ability to manage complex industrial relocations with precision and professionalism. From our use of specialist equipment to our experienced multidisciplinary team, we provided a comprehensive solution—on time and on budget— tailored to the specific needs of Ball Aerosol Packaging. If you’re considering a similar project, explore our case studies for more examples of our work. Contact us today to discuss how VIG Industrial Relocation can help you achieve your operational goals.