Client background
Shotton Mill, a leading UK-based paper mill and part of the Eren Group, is constructing one of the largest paper mills in Europe. Once operational, it will produce hundreds of thousands of tonnes of containerboard and tissue paper annually, using entirely recycled materials and sustainable energy sources.
Project scope
As part of this new paper mill, Shotton Mill required the installation of advanced OCC (Old Corrugated Containers) recycling equipment as part of a major upgrade to its PM3 OCC line to enhance the mill’s recycling capabilities and efficiency. VIG was selected as the contractor to carry out the installation due to our extensive experience in heavy machinery relocation and installation. Our role involved the full installation of key OCC processing equipment, including:
- Bale handling system (two parallel lines)
- Pulping system (two parallel lines)
- Cleaning and screening systems (multi-stage)
- Fractionation and thickening systems
- Reject handling system
Our world-class riggers, welders, and mechanical fitters worked on-site to ensure a seamless installation process, using specialist plant equipment, including overhead cranes and forklift trucks, to position heavy machinery with precision.
Challenges & solutions
- Complex equipment handling: The installation required precise alignment and positioning of heavy machinery within an operational mill environment. Our expert rigging team, supported by overhead cranes and forklift trucks, ensured safe and accurate placement
- Tight schedule: The project was completed over 12 months, requiring careful planning to minimise disruption to existing operations. Regular coordination meetings and progress tracking helped us stay on schedule
- Coordination with multiple stakeholders: Working alongside Valmet’s technical supervision, our team adapted to evolving requirements, ensuring efficient problem-solving and execution
- Safety and compliance: Adhering to strict UK health and safety regulations, VIG provided comprehensive risk assessments, method statements, and toolbox talks throughout the project
Execution & key achievements
The execution phase required a methodical approach to ensure minimal disruption to Shotton Mill’s ongoing operations. VIG implemented a phased installation strategy, allowing sections of the new OCC equipment to be integrated without affecting overall productivity. This approach was particularly important given the scale of the machinery being installed. Our engineering team worked closely with Shotton Mill’s operational staff throughout the project, to ensure seamless integration. Modern lifting techniques and precision alignment tools meant that every component was placed accurately, ensuring long-term operational efficiency. A key achievement was our ability to complete the project within budget despite unforeseen logistical challenges. By employing strategic resource allocation and flexible scheduling, any potential cost overruns were mitigated.
Results & client benefits
- Successful installation: The OCC equipment was installed efficiently, enhancing Shotton Mill’s recycling capabilities
- Operational efficiency: The new system improved processing capacity, allowing for greater efficiency in handling recycled materials
- Enhanced Sustainability: The site’s commitment to sustainability has strengthened, with the increased use of entirely recycled materials and reliance on sustainable energy sources
- Minimal disruption: Through strategic planning and execution, we completed the project with minimal downtime to the mill’s operations
- Safety & compliance excellence: The project adhered to stringent safety standards, ensuring a secure working environment. Most importantly, there were no health and safety breaches or accidents, and the project was completed without incident or injury
- Cost-Effective Execution: Despite the complexity of the project, VIG managed to keep costs under control while maintaining high standards
Delivering excellence in industrial installation
Through precise execution, expert project management, and seamless coordination with stakeholders, we ensured that the mechanical installation and plant relocation project was completed on time and to the highest industry standards. Our ability to adapt to challenges, maintain stringent safety protocols, and provide high-quality installation services solidifies VIG as a trusted partner in industrial and recycling sector projects. Contact us If you have a similar project requiring expert machinery installation, contact VIG today to discuss your requirements.
Key Facts:
- Duration: 12 months
- Job Value: £1.4m, rising to £2.5m
- Rigging, mechanical, welding, fitting
- Overhead crane
- Forklift truck