A new production line is being added. An older machine needs to be replaced. The production layout needs to be optimized to shorten distances and improve throughput times. What looks like an internal matter on paper is, in practice, a technically challenging project with clear requirements for planning, equipment, and skilled personnel.
The relocation of machinery within a facility is one of the most common reasons for inquiries to A & P Industriemontage. We have been carrying out such projects since 2004, from the initial assessment to commissioning at the new location within the facility.
In-plant machine relocation, machine relocation, and machine movement within a facility all refer to the same process: a machine or piece of equipment is moved from one location to another within the same facility. No change of location, no use of public transportation routes, and no customs clearance.
What remains unchanged: the technical effort involved. Dismantling, in-plant transport, reassembly, utility connections, alignment, and calibration: all of these steps are just as necessary for a ten-meter move within a factory as they are for a relocation across Germany. Anyone who underestimates this risks machine damage, production downtime, and subsequent safety hazards.
In industrial practice, there are a handful of situations that consistently lead to in-plant relocations:
Material flows are being reevaluated, walking distances shortened, and workstations brought closer together. As a result, machines must be repositioned.
A new system is being added. Existing machines must be moved or repositioned so that the line can operate.
An older machine is being replaced. Before the new one can be installed, the old one must be properly dismantled and removed.
Two production areas are being merged, and a new area is being set up in an existing facility. Machinery must be adapted to the new layout.
Changes in occupational safety or ergonomic requirements make a different layout necessary.
Production continues while part of the facility is being reorganized. Precise scheduling is especially important here.
“In-plant” sounds less significant than it actually is. In practice, in-plant transfers often involve exactly the same requirements as external ones—and sometimes even more challenging ones.
Narrow aisles, low clearance heights, and rows of machinery that cannot be moved. These factors severely limit the choice of transport equipment. A forklift isn’t always the solution.
Moving heavy machinery on an unknown indoor floor surface is risky. At the new installation site, the load-bearing capacity must be checked, as must the floor quality for the foundation.
Vibrations caused by lifting operations, dust generation, noise, and safety distances from running equipment: All of these factors must be coordinated to ensure that the relocation does not disrupt or endanger the rest of the operation.
Many manufacturing facilities can only move machinery during narrow time windows—between shifts, during scheduled maintenance shutdowns, or on weekends. This necessitates meticulous advance planning.
If the machine requires a foundation at its new location or if floor anchors need to be repositioned, this must be planned in advance, not during the relocation.
Moving machines within the warehouse means that most of these factors apply simultaneously, in a confined space, and often under time pressure.
Before disassembly, the machine is thoroughly documented: its technical condition, media plans, installation dimensions, foundation conditions, and photographic documentation of all connections and positions. This documentation is not merely a formality; it serves as the foundation for a flawless reassembly.
The new installation location is determined, and the transport route through the warehouse is analyzed. Bottlenecks are identified, floor load-bearing capacities are checked, and the required lifting equipment is determined. Depending on the weight and space constraints, various systems may be considered: lifting frames, heavy-duty rollers, air cushion technology, or electric forklifts.
The machine is disconnected from all media in the correct order: electrical, hydraulic, pneumatic, and cooling water. Errors in this sequence can result in consequential damage to the machine, the lines, or both. A & P handles the mechanical, hydraulic, and electrical disassembly as a one-stop service.
Transporting equipment within a facility is no simple task. Heavy-duty casters allow heavy machinery to be moved across smooth floors without having to disassemble the machine itself. Air cushion technology comes into play where heavy-duty casters fail due to uneven flooring. Lifting frames are used to address height differences or for operation in confined spaces. Choosing the right system is critical in determining the time required and the risk of damage.
This is the most technically challenging step of the entire relocation process. A machine that is not precisely aligned after being moved will produce results outside the tolerances—sometimes immediately apparent, sometimes only after weeks. A & P aligns machines according to the installation plan, using precision leveling, a theodolite, or laser measurement. Precise alignment and calibration are among our team’s core competencies.
All utilities will be properly reconnected at the new location: electricity, compressed air, cooling water, and hydraulics. This will be followed by a comprehensive functional test of all systems before production is approved.
A & P supports the restart process: test run, machine break-in, and production quality checks. If necessary, our technicians remain on site until the system is producing reliably and on schedule.
Relocating machinery—even if it is purely an internal move—is not a process that has no implications under safety regulations. Operators have clear obligations.
As soon as a machine is moved to a new location, it is considered to have been modified under the Industrial Safety Regulation. This means that a new risk assessment must be conducted before the machine is put back into service. Electrical equipment must be inspected in accordance with DGUV Regulation 3 (formerly BGV A3).
The new installation location, changes to utility connections, and the inspections performed must be documented to provide evidence to government agencies and workers’ compensation associations.
If environmental conditions change at the new location—for example, due to different soil conditions, new neighboring machinery, or altered access routes—an updated risk assessment is required.
A & P conducts safety inspections in accordance with DGUV standards as a standalone service and can perform these immediately following the relocation.
There are cases where a company’s own staff can realistically handle a machine relocation: small, lightweight machines, short distances, no foundation work, no utility line modifications, and sufficiently qualified in-house personnel.
In most industrial projects, the reality is different. An external service provider like A & P makes sense when:
A & P assigns a dedicated point of contact for every project, from the initial site visit through to commissioning. No need to coordinate between different trades. No turf wars between electricians and mechanics. One team that can do both.
Based on over 20 years of experience in industrial assembly, we see certain mistakes time and time again:
Media plans are missing, and installation dimensions were never recorded. Dismantling begins without a basis, and reassembly turns into detective work.
The machine has been removed, but the path to the new location hasn’t been measured. You only realize there’s a bottleneck once the machine is already halfway through.
This is a real risk, especially in older indoor facilities. In the worst-case scenario, the floor could collapse.
Hydraulic lines disconnected while under pressure, coolant not completely drained, electrical connections disconnected in the wrong order. Any of these errors can damage the machine.
After the relocation, the machine is set up “roughly.” A few weeks later, quality issues arise in production, the cause of which is not immediately apparent.
The machine is running again, but the DGUV inspection following the relocation was never carried out. In the event of damage, this could have consequences for the operator’s liability.
A & P Industriemontage provides comprehensive machine relocation services. Our teams handle mechanical, hydraulic, and electrical work, so you don’t have to coordinate multiple service providers.
Are you planning to relocate machinery in your production facility? Contact us. We’ll visit your site and provide specific advice on the process and implementation.
Even when moving machinery across just a few meters of floor space, it’s not something you can just do on the side. Professional planning, alignment, utility connections, and safety inspections protect the value of the machinery, production time, and personnel. A & P Industriemontage has been supporting machinery relocations since 2004, with the goal of ensuring that the equipment runs just as reliably at its new location as it did before.
Official approval is generally not required for in-plant relocations, as no public traffic areas are used and there is no change of location. However, the following remains mandatory: updating the risk assessment for the machine at its new location and conducting a periodic inspection of electrical equipment in accordance with DGUV Regulation 3. Anyone who fails to take these steps after the relocation is not acting in compliance with the law and bears an increased liability risk in the event of damage.
That depends on the machine’s size, the scope of the equipment, and the available space in the facility. A single machine that does not require foundation work can often be relocated within a shift window of eight to twelve hours. More extensive relocations involving multiple machines or the need to reroute utility lines require several days of planning and execution. A & P determines the timeline after an on-site inspection to ensure your production schedule remains on track.
A new CE marking is generally not required as long as the machine is not significantly modified. However, the following applies: As soon as a machine is moved to a new location, the operator must verify whether the safety-related conditions at the new site have changed. The Industrial Safety Regulation requires an updated risk assessment. Electrical systems must be re-inspected in accordance with DGUV Regulation 3. A & P conducts these safety inspections with certified electricians and provides the necessary documentation.
Yes, this is possible and, in many projects, necessary. However, it requires particularly careful planning: safety distances from operating equipment, dust protection, noise minimization, and clear time slots for lifting and transport operations must be established in advance. A & P has many years of experience with relocations during ongoing operations and coordinates every step with the production manager before work begins.
In industry terminology, both terms are often used interchangeably. The term “machine relocation” generally describes the entire process—that is, disassembly, transport, and reassembly—regardless of whether the destination is internal or external. “Machine relocation” or “machine move” refers to the same process, with an emphasis on internal, site-specific relocation. For A & P, this distinction makes no practical difference in the scope of services: planning, professional disassembly, transport, alignment, utility connections, and commissioning are always included.
At A & P Industriemontage, we support companies worldwide in the installation and commissioning of complex industrial plants. With our expertise and comprehensive range of services, we ensure efficient and safe production processes. Rely on our many years of experience and let’s work together to successfully implement your projects.
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