FFS Machine Relocation Services

Major Equipment Relocation Across the Country

This project involved a large-scale FFS (Form-Fill-Seal) machine relocation for one of our most strategic clients in the food manufacturing industry. The client had invested over £200 million in a state-of-the-art production facility, designed to enhance efficiency, expand capacity, and future-proof operations for decades to come.

The Challenge

The FFS machine was not only large and complex, but also still partially in use when our team began the project. Since production at the old facility could not be interrupted, our engineers had to create a meticulously planned relocation schedule. As is critical in the food manufacturing sector, maintaining product flow was a top priority.

Industrial FFS machine relocation VFFS machine inspection and servicing Flow wrapping machine reliability fix in Essex
Professional installation and commissioning of VFFS machine Industrial FFS machine relocation VFFS machine inspection and servicing Flow wrapping machine reliability fix in Essex

The Move

Our team coordinated a full disassembly of the FFS machine with assistance from the Original Equipment Manufacturer (OEM).
Key steps included:

  • Safely maneuvering the machine out of the old facility using machinery skates

  • Craning and transporting it 200+ miles across the country

  • Delivering and re-skating the machine into position at the new site

Despite improved infrastructure at the new factory — such as flat floors and modern utilities — careful planning was essential to navigate around a live operational production environment.

Reassembly & Commissioning

Once relocated, the FFS machine underwent a full installation and commissioning process, including:

  • Precise reassembly with OEM engineers

  • Connection of electrical, water, air, and cooling services

  • Integration with site systems including kitchen and CIP (Clean-In-Place) pipelines

  • Testing communication signals and process automation links

Industrial FFS machine relocation VFFS machine inspection and servicing Flow wrapping machine reliability fix in Essex

We carried out a phased testing approach:

  1. Water testing & dummy CIP cycles (checking for leaks and valve performance)

  2. Caustic CIP testing for sanitation validation

  3. Full commissioning with live product, gradually scaling run durations and product variations

Each step was carefully monitored to ensure sealing integrity, accurate filling, and operational stability.

Results

The FFS machine relocation project was delivered on time and with minimal disruption to production at both sites. Today, the machine operates seamlessly at the client’s new £200M facility, forming a key part of their upgraded production strategy and supporting their long-term growth.