About the Project
A roofing products manufacturer was overhauling its packaging operations to increase throughput and reduce manual handling. The project involved replacing manual winding and packaging processes with a fully automated system, including conveyance, tubing insertion, shrink wrapping, and robotic palletizing.
More than 30 pieces of automation equipment from various OEMs were integrated into the line. Due to the complexity, the customer sought a single-source partner with deep experience in precision installation and alignment.
Project context:
- Over a year of planning and design before install
- Critical project for plant performance and output
- Required layout accuracy, fast turnaround, and install of multi-OEM equipment
The Scope
Lovegreen was selected to provide layout measurement, equipment staging, and full mechanical installation services under a compressed timeline.
Key responsibilities included:
- Demolition and removal of select existing equipment
- Uncrating and staging of 30+ new machines
- Precision layout using conventional optical tooling
- Installation of equipment per layout drawings
- Compressed 12-day timeline with a 9-person crew
Equipment Installed:
- Core Inserter
- Shrink Wrapper
- Robotic Palletizing Cell
- Stretch Hooder
- Conveyors, guarding, and compressed air piping
Specialized Tools Used:
- Optical set for layout verification
- Two 19,000 lb forklifts
- Machinery skates and toe jacks
The Result
Lovegreen served as the customer’s primary mechanical partner, coordinating install logistics, layout accuracy, and labor management across all phases.
Project outcomes included:
- Completed 3 days ahead of schedule through effective crew sequencing
- 9-person crew split into two teams starting from opposite ends of the line, meeting in the middle for efficient progression
- Early involvement in staging allowed the team to preview equipment and plan the install flow strategically
- Customer remained on track for system commissioning with no layout or timeline disruptions
