Case Study

Large Beverage Manufacturer Factory Extension

Case Study

Large Beverage Manufacturer Factory Extension

Tying together the new plant area and the existing structure post-extension presented challenges in terms of design compatibility, utility connections, and ensuring a seamless transition between the two.

TEG Projects were brought on board for this large factory extension project. The client is a major drinks manufacturer and it was essential their factories continued to run at full capacity. Therefore in preparation for a new production line, minimising plant downtime was top of the list.

Client Information

Our client is a large-scale beverage manufacturing organisation, operating within multiple markets and supplying a wide range of customers through established distribution networks. The business forms part of an international food and beverage group.

The organisation produces and distributes a diverse portfolio of non-alcoholic beverages, supplying high-volume retail and distribution channels and operating within complex, hygiene-critical manufacturing environments.

Goal

The goal was to extend the factory building, to make way for a new production line, while minimising plant downtime and maintaining hygienic conditions.

Why TEG Projects

This was an extensive project encompassing multiple moving parts, too large for one project manager. Therefore the job was broken into parts, and the construction portion was given to TEG Projects to manage.

Solution

The solution involved the least disruptive approach. Making sure the factory could continue to manufacture beverages concurrently alongside the construction project. A temporary partition was constructed to distinguish the operational facility from the demolition and construction activities involving the old building’s removal and the establishment of the new plant area. This barrier was hermetically sealed against the facility walls, ensuring an airtight enclosure. Consequently, the facility could continue its operations unhindered while the external project proceeded.

The Air Handling Unit (AHU) operated continuously, maintaining positive pressure within the plant room and offering an additional layer of defense against construction-related dust.

Subsequently, upon the completion of the plant room extension, an additional provisional wall was put in place. This facilitated the connection between the two structures.

The entire process was meticulously planned to optimise the two-week shutdown window.

Challenges

Site Access
Existing site access arrangements were impacted by the building upgrade, requiring temporary access solutions to be reconfigured at multiple stages throughout the project. Maintaining safe and effective access for both construction personnel and operational staff was critical. Shared use of key logistics areas meant careful planning, sequencing, and on-site supervision were required to safely manage concurrent activities.

Project Timelines
Construction activities needed to be carefully coordinated to align with a planned, short-duration plant shutdown. This required precise scheduling and close management to ensure all works were completed within the shutdown window, minimising disruption to operations. The project was delivered without any unplanned outages.

Brownfield Environment
Integrating new plant infrastructure with existing facilities introduced complexity around design coordination, utility connections, and constructability. A number of undocumented services were identified, traced, and managed prior to demolition activities commencing. Additional upgrades to existing services were also required to support the new plant extension.

Results

The factory extension was completed as laid out in the initial plans. The demolition and construction phases were performed safely and on time. The production plant experienced no unplanned downtime. All of which enabled the sequential phases of the project to run smoothly.

Capabilities

Service Areas

Project
Management

Construction
Project
Management

Large Beverage Manufacturer Factory Extension