A New Plant, Built Right the First Time and Commissioned on Schedule
A family-owned packaging exporter designed and commissioned a growth-ready greenfield facility on schedule, built exactly to drawing with no design change during construction.
Built to drawing
No design changes during construction
On-time commissioning
On schedule
Commissioning
23 markets served
Export scale
AMR + articulated forklifts
Handling
Rack-supported mezzanine
Storage
The Situation
The new site needed to support multi-year growth and export complexity, not just current volume.
The major risk was design drift during execution — where late layout reality causes schedule and cost escalation.
The business needed buildability certainty before steel and civil commitments.
What We Did
We designed for actual run conditions and validated layout decisions on site before construction start.
- Sized future capacity and specified machinery for projected growth.
- Designed L-shaped material flow and inventory norms for RM, WIP, and FG.
- Built automation in from day one with articulated forklifts, AMR systems, and rack-supported mezzanine storage.
- Validated operations-fit and issued detailed cost estimate before build start.
The Results
The plant was commissioned on schedule and constructed exactly to design with no construction-stage modifications.
The facility came online certification-ready with integrated automation and growth-sized capacity.
The pre-build estimate held through commissioning, improving financial confidence at board level.
- 01
Greenfield value comes from designing for future plant behaviour, not current constraints.
- 02
When design is validated on operations reality before build, schedule and budget hold.
Industrial Businesses Across 3 Continents