Relocating a packaging line is one of the most complex engineering projects a manufacturer can undertake — and the risks are high. Packaging line relocation affects production output, product quality, operational safety, and overall business continuity. For Food, Beverage, and FMCG manufacturers, every hour of downtime has a direct financial impact.
The good news? With the right planning and specialist engineering support, it is possible to relocate a packaging line without unnecessary downtime. At Packserve, we’ve managed relocations for sites across the UK, ensuring smooth transitions, controlled dismantling, and fast reinstallation.
Here’s a practical, step-by-step guide based on real engineering processes.
Why Packaging Line Relocation Needs Careful Planning
Packaging lines aren’t just a series of standalone machines, they are interconnected systems. If one machine is misaligned, poorly calibrated, or incorrectly installed, the entire line suffers.
Downtime during a relocation can lead to:
- Missed production targets
- Increased labour and material waste
- Delays in customer orders
- Quality issues during restart
- Stress on already-stretched engineering teams
That’s why successful relocations require a structured, methodical approach.
Step 1 – Initial Assessment & Project Planning
Site Survey
An engineering team visits your current and new site to assess access routes, utilities (air, water, power), floor space, and environmental factors.
Requirements Analysis
This includes confirming your production volumes, deadlines, shift patterns, and equipment goals. It’s essential for planning a relocation without interrupting operations.
Timeline Planning
A realistic timeline is created, aligning the relocation with your production schedule, often performed during shutdown windows or staged transitions.
Step 2 – Equipment Mapping & Documentation
OEM Manuals, Drawings & Layouts
All technical documentation is gathered to ensure each machine is reinstalled exactly to OEM specification.
Line Flow Analysis
Engineers assess how products move from one machine to the next. Any change in layout can affect speed, labelling accuracy, fill levels, or packing performance.
Identifying Dependencies
This includes conveyors, guarding, networking, control systems, and utilities. Overlooking these can cause major delays after installation.
Step 3 – Controlled Dismantling
A line should never be dismantled quickly. Every step must be documented.
- Components are removed carefully and systematically
- Every cable, hose, or part is labelled
- Machines are isolated from utilities safely
- Sensitive parts are boxed and protected
This is where specialist engineers make the biggest difference, experience prevents costly mistakes.
Step 4 – Transport & Logistics Management
Safe transport is critical for preventing damage.
- Machinery is secured, wrapped, and protected for transit
- Temperature or moisture-sensitive components are handled appropriately
- Transport is scheduled to align with install teams
- All deliveries are tracked and coordinated
A well-planned logistical process is one of the main reasons relocations stay on track.
Step 5 – Reinstallation & Integration
Equipment Placement & Alignment
Machines are placed according to the new layout and checked for alignment, levelling, spacing, and accessibility.
Utilities Connection
Compressed air, vacuum, electrics, and water must match the machine’s requirements exactly.
System Integration
Conveyors, sensors, safety systems, and communication interfaces are reconnected and tested.
Step 6 – Testing, Commissioning & Optimisation
This is where the newly relocated line comes back to life.
- Dry tests (no product)
- Wet tests with product
- Fine adjustments to speed, temperature, fill volume, tension, label alignment, or pack formation
The goal is to ensure the line performs at or above — pre-relocation levels.
Step 7 – Ongoing Support After Relocation
Even a successful relocation benefits from follow-up support.
- Performance monitoring
- Engineering checks
- Preventative maintenance
- Further optimisation based on early production results
This ensures reliability long after the relocation is complete.
How Packserve Ensures a No-Downtime Relocation
Packserve provides a turnkey relocation service backed by over 30 years of engineering experience. Our teams manage:
- Full project planning
- Controlled decommissioning
- Safe dismantling
- Transport coordination
- Reinstallation & commissioning
- OEM-level setup and reporting
We work around your production schedule to minimise disruption and ensure rapid return to full output.
When Should You Consider a Line Relocation?
Manufacturers typically relocate their lines when:
- Moving into a new facility
- Expanding production capacity
- Reconfiguring floor space
- Upgrading older areas of the factory
- Introducing new machinery that changes the layout
If planned properly, a relocation can increase efficiency as well as space.
Final Thoughts
Packaging line relocation doesn’t have to cause downtime or stress. With structured planning and expert engineering support, your transition can be smooth, safe, and efficient.
Considering a packaging line relocation? Speak to our engineering experts today.
📞 +44 (0) 1254 760 123
📧 info@packserve.co.uk
🌐 www.packserve.co.uk