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Shawpak is a leading UK manufacturer of innovative packaging machinery for the medical device sector. Their product range includes rotary thermoforming, pouch, and rigid blister machinery — all designed and built in-house to the highest standards of precision and hygiene.
Client Overview
Following a period of sustained growth, Shawpak secured £500,000 in funding through the Midlands Engine Investment Fund II (MEIF II) to support their next phase of expansion. The funding enabled the company to relocate from its existing premises in Allenton, Derby to a larger, modern 27,000 sq ft facility at Stud Brook Business Park, Castle Donington.
The move provides additional space to accommodate larger production equipment, expand manufacturing capacity, and scale up Shawpak’s service and spares operations. Around 50 employees have now transitioned to the new site, positioning the business for continued growth.
Project Scope
Merritts was appointed to manage the factory relocation from Shawpak’s Derby premises to the new Castle Donington site.
A key milestone in the project involved the relocation of Shawpak’s extensive in-house machine shop, where all tooling and precision components are manufactured. This required careful coordination to minimise downtime, avoid disruption to production, and ensure every piece of equipment was transported and reinstalled safely.
Our Approach
From the outset, Merritts’ project management team focused on delivering a safe, efficient, and precisely executed move. A comprehensive lifting and movement plan was developed to coordinate every stage of the factory relocation and ensure full compliance with health and safety regulations.
Key considerations included:
- Safe handling of oversized and heavy machinery within restricted site access areas
- Protecting existing floor surfaces to maintain the integrity of both facilities
- Selecting the most suitable lifting and transport equipment for confined indoor and outdoor manoeuvres
- Ensuring minimal disruption to Shawpak’s operations throughout the transition
All works were carefully scheduled to ensure continuity of production and alignment with Shawpak’s operational deadlines.
Execution
The relocation was completed over five days.
- Preparation and uplift of all machinery, equipment, and ancillary components at Shawpak Medical Packaging Solutions, Allenton, Derby
- Transfer to the dedicated loading area and secure loading onto Merritts’ specialist transport vehicles
- Delivery to the new Stud Brook Business Park facility in Castle Donington
- Offloading, positioning, levelling, and bolting down of all machinery and equipment in accordance with Shawpak’s layout plans
Each phase was overseen by Merritts’ on-site team of engineers, ensuring that all works were completed safely, efficiently, and to schedule.
Outcome
Thanks to meticulous planning and execution, the relocation was completed on time, within budget, and without disruption to Shawpak’s production.
The move marks a significant step in Shawpak’s growth journey, providing the infrastructure needed to increase capacity and innovation.
Summary
Merritts’ expertise in factory relocation and heavy machinery transport ensured Shawpak’s transition to their new manufacturing site was seamless, safe, and precisely managed. The project reflects Merritts’ commitment to providing turnkey relocation solutions that enable manufacturers to expand and modernise their operations with confidence.
