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Our client, a leading pharmaceutical manufacturer, required the complete relocation of a production facility from their UK site to a new, larger facility in Germany. The project involved the precision movement of highly sensitive, high-value pharmaceutical production machinery including tablet presses, blister packing lines, cleanroom mixers, and climate-controlled lab equipment.
Given the critical regulatory environment, the move needed to ensure zero contamination risk, full equipment integrity, and minimal downtime. Our team was contracted to plan and execute the full relocation – including lifting, handling, transport, and reinstallation – with a strong focus on safety, hygiene, and precision.
Scope of Work
- Pre-move project planning and site surveys at both ends
- Development and submission of detailed RAMS (Risk Assessments and Method Statements)
- Decommissioning and decontamination coordination with client’s QA/QC teams
- Use of battery-powered electric forklifts for cleanroom and GMP-compliant areas
- Use of pick & carry cranes for internal relocation and compact-space lifting
- Export packing and anti-static wrapping
- Route planning and logistics for cross-border transport
- Equipment reinstallation and final positioning in Germany
Specialist Equipment & Personnel
Due to the nature of the pharmaceutical machinery and the hygiene standards of GMP environments, only non-emission, low-noise electric handling equipment was used inside the facility:
- Electric Forklifts: Emission-free, ideal for internal clean zones, fitted with non-marking tyres and precision forks.
- Pick & Carry Cranes: Compact mobile cranes used to manoeuvre large machinery in confined spaces, avoiding dismantling wherever possible.
- Heavy-Duty Air Skates and Jacking Systems: For vibration-free machine movement across sensitive flooring.
Our personnel included:
- Certified riggers and lifting technicians
- Qualified Appointed Persons for lift planning
- CPCS-qualified plant and crane operators
- Project Manager and Site Supervisor
- Health & Safety Manager
Health & Safety / Compliance
Health and safety was paramount throughout the project. Our RAMS documentation covered every step of the process including:
- Lifting plans
- Contamination control procedures
- Equipment decontamination handling
- Manual handling procedures
- Emergency response protocols
All staff underwent an on-site induction specific to the pharmaceutical environment, and worked in full compliance with client SOPs and UK/EU regulations.
Planning & Execution
Following a detailed project survey, a relocation plan was developed that phased the move across three weeks to align with the client’s production and validation schedules. This minimized operational disruption and allowed for staggered recommissioning of equipment.
- Week 1: Decommissioning, machine preparation, internal relocation to loading zones
- Week 2: Packing, cross-border transport, customs clearance
- Week 3: Equipment offload, positioning, final alignment, reinstallation
Through daily briefings and close liaison with the client’s project team, all works were delivered on time and without incident.
Outcome
The factory relocation was completed ahead of schedule and with zero equipment damage or HSE incidents. All machines were recommissioned and validated successfully in the new facility. The client praised our team’s professionalism, flexibility, and attention to detail—especially in working within stringent pharmaceutical cleanliness and documentation standards.
“Your team’s planning and execution were flawless. The move was one of the smoothest we’ve experienced, and your understanding of GMP environments gave us full confidence throughout the process.”
Project Manager, Global Pharmaceutical Client
