Greenfield projects
Land to line, run by people who have commissioned one.
A greenfield build is the one moment you get to decide how a plant will behave for the next twenty years. We run the project end to end — feasibility, design, procurement, construction supervision, commissioning and ramp — and we design the intelligence in while it is still cheap.
How it runs
Six stages, each with an exit test
Nothing moves to the next stage on optimism. Every stage has a document, a decision and someone who signs it.
Stage 01 · Weeks 1–6
Feasibility & business case
Demand case, capacity model, site options, capex envelope and operating cost per unit at three volumes.
- Site comparison against power, water, labour, logistics and incentive position
- Capacity model tied to a demand scenario, not to a wish
- Capex envelope and payback the board can approve
- Go / no-go with the risks named
Stage 02 · Weeks 4–14
Design & data architecture
Layout, material flow and line balance settled on paper — and the data architecture drawn at the same time.
- Block layout, flow and storage strategy
- Line balance and manpower norms at target rate
- Network, sensing and MES/ERP architecture designed with the layout
- Utility loads sized from the process, not from a rule of thumb
Stage 03 · Weeks 10–26
Procurement & vendors
Equipment specified to your process, evaluated technically, negotiated commercially and controlled to delivery.
- Technical specifications written to the process
- Vendor long-list, technical evaluation and reference visits
- Commercial negotiation support and contract terms
- Expediting, inspection and delivery control
Stage 04 · Weeks 20–44
Build & installation
Civil, utilities and equipment installation supervised against the design rather than against the invoice.
- Civil and utility works supervision
- Equipment erection and alignment
- Safety systems and statutory approvals
- Change control when reality argues with the drawing
Stage 05 · Weeks 38–52
Commissioning & people
Validation, trial runs, standard work written on the shift that will use it, and the team certified before rate.
- Dry and wet commissioning, trial batches
- Standard work written with the operators
- Skills matrix, certification and shift structure
- SOPs, quality plan and maintenance plan live before rate
Stage 06 · Weeks 48+
Ramp & handover
Rate, yield and OEE driven to plan, then handed to a team that can hold it without us.
- Ramp curve tracked against plan, weekly
- OEE, yield and energy per unit to target
- ESG baseline established from day one data
- Handover against an agreed exit number
Why now, not later
Retrofitting intelligence costs several times what designing it in does.
Cable routes, sensor positions, panel space, network drops and the floor loading for future automation are almost free on a drawing and expensive in a finished building. The same is true of quality: a process designed to be capable is cheaper than one inspected into compliance afterwards.
- Sensing and network designed with the layout, not chased through a live plant
- Utility metering built in, so the ESG baseline exists from day one
- Standard work written during commissioning, while the reasons are still fresh
- Maintenance strategy set before the warranty period, not after it
Next step
Have a site, or only a business case?
Either is a good place to start. The first conversation is about what you are trying to make, at what rate, and by when.