Large-scale aseptic bottling line relocation

The challenge

A global food & beverage producer required the full relocation of a large and highly complex aseptic bottling and filling line. The project involved dismantling an operational production line in Seville (Spain), transporting it to long-term storage, and rebuilding it at a new production site in Denmark.

The challenge was multifaceted: strict hygienic requirements due to the aseptic nature of the line, oversized and exceptional transport dimensions, tight on-site timelines, and a long-term, phased project planning across multiple countries.

The solution & execution

Gerritsen Group delivered a fully managed, end-to-end solution — from engineering and dismantling to transport, storage and future reinstallation. Key phases of execution:

• Lift & shift operations for oversized components, including exceptional loads up to 5 meters high
• Custom packaging tailored to aseptic and long-term storage requirements
• Coordinated logistics involving 48 truckloads, including 8 exceptional transports
• Secure warehouse storage for a minimum of one year at Gerritsen Group facilities
• Future relocation and rebuild in Denmark, including recommissioning and recertification of the aseptic line

All dismantling activities were completed within a 6-week on-site window, fully packaged, loaded and transported according to plan.

The result

The complete aseptic production line was safely dismantled, preserved and stored without compromising quality or certification requirements. The project ensured full value retention of a highly specialised production asset and enabled a smooth transition to its next lifecycle phase.

After relocation to Denmark, the line will be rebuilt and recommissioned for water bottling, including full cleaning, re-flushing and recertification according to local regulations. The rebuild phase is scheduled to take approximately 10 weeks, following a long-term planning horizon of 6–12 months.