Projects Flagship Case Study

Relocation & Re-Commissioning of a Complete Feed Mill Plant

A high-complexity industrial relocation project delivered with full engineering control, zero asset loss, and improved operational performance.

Capacity: 20 TPH Scope: Turnkey Relocation Sector: Agro-Industrial

The Challenge

The client owned a complete feed mill plant with a production capacity of 20 tons per hour, installed at an existing location that had become operationally unsuitable. They needed to move, but faced significant risks.

  • Entire plant dismantling and relocation required.
  • New site had different spatial constraints.
  • Need to reuse existing assets to control CAPEX.
  • Critical requirement to minimize performance loss.
"This was not a simple dismantling job — it required engineering-driven relocation."

Project Objectives

The goal was not just to move the plant, but to deliver a facility that operated better than before.

Asset Preservation

Preserve full value of equipment during move.

Flow Optimization

Redesign material flow to suit new site constraints.

Process Improvement

Enhance grinding quality and process efficiency.

Operational Delivery

Handover a fully working plant, not just parts.

Our Role

Scope & Responsibility

Engineering & Re-Design

Complete assessment and layout adaptation.

  • Flow logic redesign
  • Process sequencing
  • Site adaptation

Dismantling & Preservation

Controlled removal ensuring zero damage.

  • Electrical tagging
  • Mechanical protection
  • Documentation

Logistics & Transport

Coordination of safe asset movement.

  • Loading plans
  • Sensitive equipment handling
  • Transport coordination

Civil & Structural

Site preparation and new structures.

  • Site leveling
  • Concrete works
  • New steel gantries

Electrical & Control

System upgrades and safe energization.

  • Panel redesign
  • Control logic adaptation
  • Complete rewiring

Commissioning

Process tuning and optimization.

  • Process balancing
  • Grinding improvement
  • Performance tests

Engineering Challenges Solved

Challenge 1

Site Constraints

The new site geometry did not match the original plant layout, making direct re-installation impossible.

Our Solution:

We redesigned the entire material handling logic, introducing new conveyor routes and vertical transfers to fit the space while maintaining production capacity.

Challenge 2

Asset Reuse

Old equipment needed to perform like new to ensure ROI, despite years of previous operation.

Our Solution:

We applied value engineering, selectively upgrading critical wear parts and improving process flow instead of replacing major assets, saving significant CAPEX.

Challenge 3

Process Quality

The client wanted better grinding performance and product consistency than the original plant design offered.

Our Solution:

We engineered and added process improvement stages in the grinding section during re-installation, directly enhancing final product quality.

Project Delivery Flow

1

Assessment & Planning

Engineering Re-Design

2
3

Dismantling & Transport

Re-Installation

4
5

Integration & Commissioning

Operational Handover

Key Results & Outcomes

Operational

  • Capacity restored to 20 TPH
  • Improved material flow
  • Enhanced grinding quality

Commercial

  • Significant CAPEX saving
  • Maximum asset reuse
  • Controlled schedule

Strategic

  • Extended asset life
  • Future expansion ready
  • Single accountability

Project Gallery

Plant View

Relocated Plant

Dismantling

Controlled Dismantling

Commissioning

Re-Commissioning

Why This Is A Flagship Project

This project demonstrates our ability to not just move plants, but to re-engineer them. It combines full relocation capability, deep engineering integration, value engineering, and high-risk execution into a single successful outcome.

Planning a Relocation?

If you are considering relocating, upgrading, or reviving an industrial plant, this project demonstrates how engineering-led solutions can protect your investment and improve performance.

Discuss Your Relocation

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