The Complex Manufacturing Challenge: Coordinating a Major Capital Investment
Pet Food Manufacturing
£28m+ Major Project
200+ Contractors
Value Engineering
Nestlé Purina was undertaking a massive £ 28+ million investment in a new, state-of-the-art pouch production line. The key challenge was coordinating the complex site-wide installation, requiring a central management hub for a project involving over 200 contractors within an intense 10-week commissioning window. This required supreme logistical planning for a multifaceted programme.
Case Study In Numbers
Project value
£28m+
Coordination of a massive site-wide investment programme.
Workforce managed
200+
Contractors coordinated daily within a live operating environment.
Commissioning window
10 Weeks
Intense installation programme delivered safely and on schedule.
Capital savings
£200,000
Immediate savings achieved through value engineering on installation.
Energy savings
£50,000/yr
Recurring gas cost reduction via a bespoke heat recovery system.
Outcome
100% Up-Skilled
Bespoke training package delivered to permanent staff for Day 1 readiness.
The Risk: Compromised Investment and Operational Inefficiency
Without expert, centralised site management, a project of this scale faced significant risks. A lack of coordination between the numerous contractors could easily lead to costly delays, budget overruns, and poor integration of essential site services. Crucially, failing to properly train the permanent staff on the new technology would result in the multi-million-pound asset underperforming and failing to deliver its full Return on Investment (ROI).
The Solution: Embedded Project Management & Value Engineering
Legacy Manufacturing Solutions was embedded directly into the Nestlé Purina project team, providing the specialist site coordination and project management required to bridge the gap between the new equipment and the existing factory infrastructure.
Our role was to drive Value and ensure seamless execution across the entire Project Programme:
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Contractor Management: We took full command of the 200+ on-site contractors, orchestrating the intensive 10-week installation and commissioning programme to ensure it was completed safely, on schedule, and to the highest quality standard.
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Energy Recovery Scheme: We proactively managed an entire energy recovery scheme, taking it from detailed specification and design to final installation. This hands-on approach delivered immediate and substantial cost benefits.
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Automated Control System: We designed and commissioned a fully automated control package for the heat recovery system in just 10 weeks, creating a subsystem that operates with maximum efficiency.
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Staff Upskilling: Finally, we developed and delivered a bespoke training package to upskill Nestlé's permanent team, ensuring they were confident and competent to operate the new line from day one, safeguarding the asset's long-term performance.
The Outcome: Significant Savings and a Skilled Workforce
Our integration into the Nestlé Purina team was a resounding success. The project was delivered efficiently and on time, and our value engineering approach produced significant, measurable financial returns.
“By embedding our project management team and focusing intensely on value engineering, we didn't just deliver the programme on schedule; we generated an immediate capital saving of £200,000 and secured an additional £50,000 in recurring operational savings through the expertly designed energy recovery system. That is the true measure of success for a major capital project.” - Legacy Manufacturing Solutions.
Proven Results. Documented.
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