Case Study

Bottling Facility Refurbishment

Hunter Safety Group was appointed as Principal Contractor to support the delivery of project Cristiano, part of our client's ongoing refurbishment of there bottling facility. The works were delivered to support the decommissioning of redundant Line 9 equipment and the installation of a new Bottling Line 7. This upgrade was designed to improve operational efficiency and modernise the bottling hall infrastructure.

All works were carried out within a controlled CDM-regulated area on the ground floor, ensuring full compliance with health, safety, and construction management requirements while maintaining operational continuity across the live production environment.

Role

Hunter Safety Group delivered a comprehensive package of pre-construction, construction, and safety management services to support the successful integration of the new bottling line infrastructure.

During the pre-construction phase, this included project preparation activities such as site visits, client brief reviews, and the development of pre-construction information.

The construction phase involved the implementation of a comprehensive health and safety management system, including a robust Permit to Work system, and the delivery of site-specific inductions for all personnel operating within the CDM area. Daily coordination with the project team ensured that health and safety standards were maintained consistently, even during peak workforce levels.

In parallel with these management activities, Hunter Safety Group oversaw and coordinated the physical works, including the installation of reinforced foundations and the erection of a steel-framed mezzanine complete with integrated handrails and kick plates across the bottling hall and finished goods store. The scope also included installation of a robotic unit within the materials store, new flooring across the finished goods area, and upgraded drainage infrastructure around the filler lines.

Additional works included the installation of a high-level conveyor system serving the bottling hall, along with the formation of new structural openings and shutters to enable seamless integration between the bottling hall and finished goods areas.

Throughout the project, continuous monitoring, inspection, and auditing of site safety standards were undertaken, with regular reporting on health and safety performance.

Ongoing engagement with the workforce was maintained through daily briefings, weekly coordination meetings, toolbox talks, and proactive behavioural safety initiatives such as daily challenges and activity look-ahead planning. The team also provided ongoing advice in line with current health and safety legislation and CDM regulations, ensured the Temporary Works Register was maintained and inspected by competent personnel, and confirmed adequate first aid provision throughout the project. All works were delivered in alignment with Diageo’s programme and phased integration plan, ensuring safe and efficient delivery within a live operational environment.

Summary

The project was successfully completed within the designated CDM-controlled area without major disruption to ongoing site operations. Key achievements included the safe execution of high-risk activities such as mezzanine installation, robotic system integration, and high-level conveyor works.

Strong contractor coordination ensured the timely delivery of sequential and interdependent tasks, while robust planning and communication supported seamless integration with Diageo’s production requirements.

A consistent focus on safety was maintained throughout, with effective implementation of permit-to-work systems, RAMS reviews, toolbox talks, and continuous on-site supervision. This resulted in a high level of workforce engagement and safe delivery across all phases of the works.

The completed installation met Diageo’s technical standards and project specifications, with collaborative planning ensuring full alignment with the phased operational handover and refurbishment programme.