Trusted Support for a Complex Transatlantic Machinery Move

Project Snapshot

Client: UK-based manufacturer of plastic agricultural components

Secondary Client: US-based company that acquired the UK manufacturing business

Sector: Manufacturing

Locations: Cambridge, UK to Minnesota, USA

Equipment Relocated: Arburg injection moulding machines with robotic pick-and-pack cells

Our Role: End-to-end international machinery relocation

Severe Winter Weather and Transatlantic Transport Challenges

The client, a Cambridge-based manufacturer of precision plastic components used on agricultural tractors, contacted Flegg Projects for an international machinery relocation following a buyout from a US-based company in Minnesota who wanted to bring production of spray and weed control systems in house.

The client approached us due to an established relationship and prior experience as we had originally installed the injection moulding machines on behalf of Arburg and were trusted to understand the equipment, its sensitivities, and the precision required to relocate and reinstall it correctly. As well as the injection moulding machines, we were also tasked with relocating integrated robotics and pick-and-pack automation.

In addition to the technical demands of the machinery, the project faced a number of significant challenges:

  • International logistics and customs coordination
  • Long-distance sea freight
  • Extreme winter conditions in Minnesota, with temperatures as low as –40°C resulting in a frozen rail hub that prevented offloading of equipment for three weeks

Despite these risks, the expectation remained that the equipment would arrive safely, be reinstalled correctly, and return to full operational status.

Our Solution: Going the Extra Mile to Deliver Fully Operational Assets Overseas

We took full responsibility for decommissioning the injection moulding machines and associated robotic equipment at the Cambridge facility. Each machine was carefully prepared for overseas transport and secured onto custom-built pallets using Hyster S7S and Hoist 25–35 forklifts.

To protect critical metal components from corrosion during transit, all machinery was foil-bagged to eliminate moisture ingress. The equipment was then shipped to the USA via sea freight, ensuring maximum protection throughout the journey.

Upon arrival in the United States, our engineers flew out to supervise the offloading process and oversee the transfer of the machinery onto a train bound for Minnesota.

However, on arrival at the Minnesota rail hub, extreme winter weather caused the train to freeze, making it impossible to offload the machinery. As a result, the equipment remained on the train for approximately three weeks until temperatures improved and conditions were safe.

During this period, our engineers returned to the UK while maintaining close communication with both the original client and the new US owner.

Once conditions allowed, our engineers returned to Minnesota to complete the offloading, unpacking, and installation of the machinery. Working in collaboration with an international partner, specialist lifting equipment was used to position the machines safely and accurately.

Installation works included:

  • Careful positioning and alignment of machines within the production line
  • Precision re-levelling to ensure machines were installed exactly to manufacturer specifications
  • Rewiring and re-oiling of equipment
  • Full commissioning of machinery and robotic systems

We remained on site beyond installation to provide post‑commissioning support, ensuring that the equipment was fully operational and production-ready before final handover.

Due to the extreme temperatures, local safety protocols meant engineers were transported directly between accommodation and site, underlining their commitment to seeing the project through despite challenging conditions.

Despite extreme weather, extended delays, and international logistical complexity, the project was successfully delivered with all machinery was safely relocated and reinstalled to original specifications.

This project clearly demonstrates our engineer’s flexibility, adaptability, and commitment to customer care. Rather than simply lifting and shipping machinery, the team took full ownership of the equipment from decommissioning through to final commissioning, remaining involved, returning overseas when required, and ensuring the machines were not only moved, but fully operational before leaving site.

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