The Complex Manufacturing Challenge: Major Expansion Without Halting Production
Food Manufacturing
CAPEX project
Zero downtime
Allied Bakeries required a multi-million-pound redevelopment of their West Bromwich site to significantly increase capacity. This wasn't a minor project; it involved installing a new 20,000-roll-per-hour plant, six 80-tonne flour silos, and a new distribution system, along with a major site reorganisation, including relocating the main entrance.
Case Study In Numbers
Production downtime
0 hours
Live install completed with zero disruption
Roll output capacity
20,000/hr
New line commissioned to 20k rolls per hour.
Project duration
12 months
End‑to‑end delivery on schedule.
Flour silos installed
Six × 80 Tonne
Integrated alongside new distribution live.
Coordinated
100+ Contractors
Phased access with hygiene controls.
Hygienic Flexi‑Wall zone
200m × 50m
Segregation enabled works while baking continued.
The Challenge: seamless execution
The critical challenge was the seamless execution of this extensive installation—a complex manufacturing challenge—without disrupting the bakery's continuous, high-volume operations.
The Risk: Costly Downtime and Compliance Hazards
Integrating a modern production line into a live factory environment carried significant risk. Poor project management and coordination of the nearly 100 contractors on site could easily lead to catastrophic operational downtime, severe logistical chaos, or critical hygiene compromises. Any such misstep would result in a substantial financial cost to the business.
The Solution: Strategic Project Management & Innovative Segregation
Legacy Manufacturing Solutions was appointed as the expert partner, providing end-to-end project management over the full 12-month contract. Our core strategy focused on meticulous planning to ensure seamless execution and zero disruption.
The key innovation was the implementation of a sophisticated "Flexi-Wall" system. We constructed a 200m by 50m hygienically segregated zone within the operating factory. This strategic partitioning allowed major civil works on floors, roofs, and services to proceed safely and at schedule while normal bakery production continued, entirely unaffected.
Our hands-on management team meticulously coordinated every detail—from civil engineering and risk assessment to the final mechanical installation and handover.
We ensured the project adhered to the agreed timeline, stayed within budget, and met the highest health and safety and quality standards.
The Outcome: Enhanced Capacity with Zero Disruption
The 12-month programme was a decisive success, delivered on time and on budget.
Allied Bakeries now benefits from a state-of-the-art facility with massively increased production capacity. Crucially, this complete industrial Transformation was achieved with zero disruption to their existing operations, completely protecting their revenue and output throughout the project’s duration.
This case study is a perfect example of our commitment to delivering complex industrial projects with the precision and intelligence required to achieve a true zero-downtime outcome.
Proven Results. Documented.
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