Projects

Explore our diverse range of projects, showcasing our expertise in designing, implementing, and optimising advanced machinery and automation solutions for a wide range of industries.

01

Modernising an industrial shredder

Project overview

Upgraded shredder to meet safety regulations and improve workplace compliance
Focused on operator well-being, equipment performance, and maintaining production efficiency.

Challenges

Identified and addressed various safety risks
Balanced costs with necessary safety upgrades
Integrated new safety features with existing electrical systems
Minimised production halts during installation.

Solution

Conducted thorough risk assessment and safety design
Installed safeguards like barriers and emergency stops
Utilized a safety controller for streamlined operations
Pre-assembled components to save time onsite.

Results

Achieved compliance and operator safety
Reduced risks and ensured smooth machinery operation
Completed project with minimal impact on production.

02

Robot installation
for glass sealing

Project overview

Replaced an outdated sealing robot with a new model to enhance a double-glazing production line’s performance, reliability, and maintainability, all within a short three-week window.

Challenges

Limited installation time during the Christmas shutdown
Integrating new robot with older machinery, including mechanical and electrical compatibility issues
Completing commissioning before production resumed, despite holiday season support limitations.

Solution

Advanced planning, testing, and collaboration with the manufacturer ensured a smooth installation
In-house fabrication of custom parts prevented delays
Detailed project scheduling and contingency planning kept the timeline on track.

Results

Installation finished early, allowing extra testing and operator training
Customer started benefiting from the new robot sooner than expected, leading to another project engagement.

03

Modernising an Atlas/ply separater

Project overview

This project involved upgrading two industrial slitters from different manufacturers, replacing ageing DC motors and drive systems with modern AC technology and implementing a new control architecture. The aim was to improve reliability, reduce maintenance demands, and create a platform suitable for future safety and automation upgrades.

Challenges

Downtime minimisation to preserve production
Budget optimisation for component upgrades
Future-ready design for tech advancements and spare parts
Unified electrical control system for varied components
Custom motor adaptations for optimal performance
Maintenance accessibility for quicker servicing

Solution

We balanced the upgrade by focusing on performance, cost, and future benefits:

Planned upgrades to replace key parts while managing costs and ensuring reliability
Chose AC drives with built-in controls and safety to simplify wiring and hardware
Replaced old control panels with modern HMIs for fewer failures and easier updates
Designed the system for easy maintenance, like accessible filters and belt replacements
Adapted mechanics for new motors to run smoothly and efficiently.

Our strategy ensured a smooth mix of electrical, mechanical, and control systems, even with machines from different makers.

Results

The upgraded slitters provide:

Easier use for operators with modern interfaces
Less maintenance due to AC tech and better access
Remote diagnostics for quicker fixes and less downtime
A strong base for future improvements like automation and IoT

This project resulted in more reliable machines, lower costs, and a plan for future upgrades.

04

Intermac master 53 installation

Project overview
This project involved the installation of a CNC machining centre inside a fully operational glass manufacturing facility. The machine was part of an expansion of the customer’s production capability, requiring precise handling, coordination, and integration into an already constrained environment.

Challenges

The project was delivered during a global pandemic, requiring strict safety controls, reduced onsite personnel, and careful coordination to maintain progress safely.
The work was carried out in a very confined area surrounded by operating machinery and large volumes of glass, making equipment placement, personnel movement, and safety management challenging.
The facility was already densely packed with services, requiring careful planning to route and connect electrical, water, cooling, and compressed air services without disrupting existing operations.

Solution

Detailed planning of lifting and handling, using the right combination of cranes, forklifts, jacks, and specialised equipment to move the CNC safely through tight spaces.
A staged lifting approach to protect the machine and keep personnel safe, particularly near glass storage and processing areas.
Careful routing of electrical, water, and compressed air services to suitable connection points within the congested factory.
Strict compliance with health protocols to maintain safety during the pandemic while keeping the project on track.
This structured approach resulted in a safe installation with zero incidents and no impact to customer equipment or personnel.

Results

The CNC was installed smoothly, safely, and on schedule, with all services connected cleanly, minimal disruption to production, and a professional outcome that allowed the customer to bring the machine online quickly and with full confidence.

05

Machine relocation

Project overview

We provide complete end-to-end relocation solutions for industrial equipment, machinery, and full production lines, whether moving them across New Zealand or shipping them overseas. Our service covers every stage of the process—from decommissioning to reinstallation—ensuring equipment arrives safely, is reassembled correctly, and is fully operational with minimal downtime.

Challenges and objectives

Safe Decommissioning:
We carefully disconnect and dismantle equipment, clearly documenting and labelling all connections to ensure fast, accurate reinstallation.
Protection of Critical Components:
Sensitive and high-value parts are professionally packed and protected to prevent damage during transport.
Transport Planning & Packing:
We measure, plan, and pack equipment efficiently to ensure safe transport and compliance with regulations.
Cost-Effective Shipping:
We select the best transport and shipping options to balance cost, timing, and risk.
Local & International Experience:
We manage relocations within New Zealand and overseas, with proven experience in international logistics and compliance.