Efficient Solutions for Plant Relocations
Minimise downtime. Manage risks. Secure production.
A plant relocation is one of the most demanding projects in manufacturing companies. Whether relocating, expanding, modernising or strategically realigning, production facilities must be relocated safely, on time and with minimal downtime.
Without professional planning and implementation, there is a risk of production losses, machine damage, safety risks and considerable additional costs.
Unlike traditional office or warehouse relocations, a factory relocation involves moving entire production lines, factory buildings and heavy-duty equipment. Individual machines weigh several hundred tonnes, consist of highly sensitive components and must be dismantled and reassembled with precision.
Why Plant Relocations Are So Complex
Plant relocations combine technical, logistical and organisational challenges. At the same time, delivery commitments often continue while legal requirements and occupational safety regulations must be strictly adhered to.
- Size and weight of machinery: Individual machines and systems may weigh several hundred tonnes.
- Technical sensitivity: Highly sensitive components require precise dismantling and reassembly.
- Production interruptions: Any downtime directly impacts delivery capability and costs.
- Safety and legal requirements: Strict regulations must be complied with throughout the project.
- Logistics & transport: Road, rail, sea or air transport must be carefully coordinated.
These factors make plant relocations complex projects that require tailored solutions rather than standard approaches.
The Key to Success: Detailed Planning
The foundation of a successful relocation is early, structured and realistic planning. Months before the actual move, all machines, systems, media connections and production processes are systematically recorded.
This creates a transparent project structure and a reliable schedule covering all steps from dismantling to recommissioning.
- Inventory assessment: Complete documentation of machines, systems and infrastructure.
- Project and schedule planning: Definition of timelines, sequences and dependencies.
- Risk management: Identification of critical machinery, bottlenecks and fallback scenarios.
- Trade coordination: Close coordination between mechanics, electricians, logistics and project management.
- Compliance: Consideration of legal, safety and operational requirements.
Professional planning ensures transparency, control and reliable implementation.
Professional Dismantling – Precision Instead of Improvisation
The dismantling of industrial plants requires experience, technical expertise and specialised equipment. Each machine is systematically dismantled, clearly marked and fully documented.
Modern methods such as match marking and 3D scanning support the precise allocation of all components and significantly reduce errors during reassembly.
- Clear labelling & documentation: Every component is uniquely identified.
- Specialised equipment: Hydraulic lifting systems, cranes and special tools for heavy loads.
- Safety standards: Strict compliance with occupational and fire safety regulations.
- Protective packaging: Vibration- and climate-protected packaging for sensitive components.
Logistics & Transport – Tailor-Made Solutions
Transport is one of the most sensitive phases of a plant relocation. Depending on size, weight and distance, different transport routes and methods are used.
- Road transport: Heavy-duty transport for large and heavy machinery.
- Rail transport: Efficient solutions for long-distance transport within Europe.
- Sea freight: Ideal for international relocations and oversized equipment.
- Air freight: For particularly urgent or highly sensitive components.
This includes route planning, permit management, scheduling and compliance with all safety requirements.
Reassembly & Recommissioning – Safe Return to Production
At the new location, the quality of the reassembly determines the success of the entire project. Machines and systems are positioned with millimetre precision, professionally assembled and connected to all required media.
- Precise alignment: Exact positioning for reliable production.
- Media connections: Power, compressed air, gas, water and IT infrastructure.
- System integration: Integration into existing production and control systems.
- Testing & acceptance: Functional tests, fine adjustments and final approval.
Your Advantage with ORCA Industrieservice
ORCA Industrieservice provides comprehensive support for company relocations – from planning, dismantling and logistics to reassembly and recommissioning.
- All services from a single source
- Experienced specialists and modern equipment
- Clear processes and transparent project management
- Maximum safety and minimal downtime
Conclusion
A plant relocation is a complex project that requires experience, precise planning and reliable execution. With professional support, relocations can be carried out safely, on schedule and with minimal disruption to production.
ORCA Industrieservice ensures a smooth relocation process and a successful restart at the new location.