Published by BENZ Packaging Technical Team | Last Updated: March 2026
When Do Factories Relocate?
Production line relocation — also called factory shifting or plant relocation — is increasingly common across Indian manufacturing. Companies relocate production lines for several reasons:
- Capacity expansion: Moving to a larger facility to accommodate growing production demands
- Cost optimization: Relocating to states with better incentive packages (Gujarat, Tamil Nadu, Andhra Pradesh SEZs)
- Government industrial corridors: Moving into dedicated industrial zones like DMIC (Delhi-Mumbai Industrial Corridor), CBIC (Chennai-Bengaluru Industrial Corridor)
- Plant consolidation: Merging multiple facilities into a single optimized location
- Lease expiry: Shifting from rented premises to company-owned factories
Regardless of the reason, the packaging challenge remains the same: how do you disassemble, protect, transport, and reassemble an entire production line — potentially worth ?5–50 crores — without damaging a single machine?
The Hidden Threat: Corrosion During the Storage Gap
The most overlooked risk in factory relocation isn't transit damage — it's corrosion during the storage period between disassembly and reassembly. Here's the typical timeline:
- Week 1–2: Production line is disassembled and packed at the old site
- Week 2–3: Packed machines are transported to the new site
- Week 3–6: Machines sit in the new warehouse while civil work, electrical installation, and foundation preparation are completed
- Week 6–10: Machines are unpacked and reassembled
During weeks 3–6, your machines are sitting idle in an often-unfinished warehouse with open walls, no climate control, construction dust, and Indian monsoon humidity (60–90% RH). Without VCI protection, visible rust appears on bare machined surfaces within 72 hours.
The solution: every machine must be protected with VCI Paper and VCI Film at the disassembly stage, providing continuous corrosion protection throughout storage and transit. For relocations involving 4+ weeks of storage, add barrier film and desiccants.
Equipment-by-Equipment Relocation Packaging Guide
Injection Moulding Machines
Injection moulding machines — from small 50-ton units to massive 3,000-ton presses — are the backbone of plastic manufacturing. Packaging requirements:
- Hydraulic system: Drain all hydraulic oil from the power unit, accumulators, and cylinders. Cap all hose connections
- Mould platens: Clean and protect with VCI Plain Paper. These are precision ground surfaces — any rust requires expensive regrinding
- Tie bars: Wrap with VCI Crepe Paper — the stretchable paper conforms to the cylindrical shape
- Barrel and screw: For removal models, extract the screw, clean residual plastic, apply rust preventive oil, and wrap in VCI Paper
- Control panel: Seal with anti-static VCI film to protect PLCs and drives
- Mounting: Bolt machine to structural wooden skid rated for the machine weight
Conveyor Systems
Conveyors are typically the longest and most complex systems to relocate:
- Sectional disassembly: Mark and label each section for reassembly sequence
- Drive motors: Remove, wrap in VCI Film, and pack in individual boxes
- Rollers and shafts: Protect bearing surfaces with VCI Paper
- Belt/chain: Clean, detension, and coil separately. Wrap in VCI Film to prevent metal link corrosion
- Frame sections: Stack with foam separators, wrap in VCI Film, bundle with steel strapping
Press Machines (Hydraulic & Mechanical)
Presses weighing 5–80+ tons require heavy-duty handling:
- Ram lockdown: Lock the ram in the fully closed position to prevent movement during lifting
- Slide gibs: Protect precision ground surfaces with VCI Paper strips
- Hydraulic system: Complete drain. Cap all fittings. Place VCI Emitters inside the hydraulic tank
- Die area: Remove dies and pack separately. Clean and VCI-protect the die mounting surfaces
- Transport: Heavy-duty wooden skids with steel cross-bracing. May require low-bed trailer for road transport
Industrial Pumps
- Drain all process fluid and flush the pump casing
- Protect impeller and shaft: Wrap with VCI Crepe Paper — conforms to the complex impeller geometry
- Mechanical seals: These are the most expensive wear parts. Protect from impact with foam cradles inside a VCI Film enclosure
- Pack in wooden boxes with foam lining. Add silica gel desiccants for humidity control
Electrical Panels, PLCs & Control Systems
- Photograph everything before disconnecting — wiring, cable routing, panel layouts, PLC configurations
- Label every cable with both ends marked (source ? destination)
- Wrap panels in anti-static VCI film
- Remove PLCs and drives where possible. Pack in ESD bags inside foam-lined cases
- Add desiccants inside each panel box — electronic components are extremely sensitive to condensation
The 4 Phases of Production Line Relocation Packaging
Phase 1: Pre-Move Audit (1–2 Days)
BENZ packaging engineers survey every machine on the line, documenting dimensions, weight, fluid contents, electrical connections, and special requirements. A detailed packaging plan and timeline is produced.
Phase 2: Disassembly & Packaging (5–15 Days)
Our crew of 20+ trained packaging specialists works machine-by-machine through the production line. Each machine is photographed, labeled, disassembled (where necessary), cleaned, VCI-protected, and crated or skid-mounted. A detailed inventory manifest is created.
Phase 3: Transport Coordination (1–5 Days)
We coordinate with your logistics team on truck types (flatbed, low-bed, enclosed), loading sequences, route surveys for oversized equipment, and unloading requirements at the new site.
Phase 4: Unpacking Support (Optional)
BENZ can provide unpacking supervision at the destination to ensure machines are removed from crates correctly, VCI materials are properly disposed of (they are recyclable), and any transit damage is documented immediately for insurance purposes.
BENZ's On-Site Packaging Capability
Unlike packaging companies that require you to transport machines to their facility, BENZ provides complete on-site packaging. Our Gurugram-based crew arrives at your factory with:
- Complete VCI paper, film, barrier film, and desiccant inventory
- ISPM-15 certified pre-cut lumber and plywood
- Portable heat-sealing equipment for VCI and barrier film
- Power tools, fasteners, and steel strapping systems
- Forklifts and rigging equipment (for facilities without crane access)
We serve factory relocations across India — from the automotive belt of Pune-Chennai-Manesar to emerging industrial corridors in Indore, Hosur, and Greater Noida.
Checklist: What to Ask Your Packaging Partner Before a Factory Move
- Do you provide on-site packaging, or must we transport machines to your facility?
- Do you use VCI (Volatile Corrosion Inhibitor) protection for machined surfaces?
- Can you handle multiple machine types (CNC, press, injection moulding, electrical panels)?
- Is your wooden packaging ISPM-15 certified?
- Do you provide a detailed inventory manifest with photographs?
- Can you coordinate with our logistics team for loading and transport?
- What is your crew size and how many machines can you pack per day?
- Do you install impact, tilt, and humidity indicators?
- What is the expected protection duration of your VCI materials?
- Will you provide unpacking supervision at the destination?
Frequently Asked Questions
How long does it take to package an entire production line?
A typical line with 15–25 machines takes 5–10 working days. BENZ deploys a crew of 20+ members. Larger facilities with 50+ machines require 15–20 days.
What is the biggest risk during factory relocation?
Corrosion during the storage gap between disassembly and reassembly. Machines often sit in warehouses for 2–8 weeks. Without VCI protection, exposed precision surfaces rust within days in Indian humidity. Read the complete protection methodology.
Do I need VCI protection for machines moving within the same city?
Yes, if there is any storage gap. Even 3 days in an open warehouse can cause visible corrosion on bare surfaces in 60–90% RH conditions. VCI paper and film add minimal cost but prevent expensive rework.
Can BENZ handle injection moulding machine packaging?
Yes. We handle machines from 10 ton to 3000 tons clamping force — hydraulic drainage, platen protection, tie bar wrapping, barrel/screw protection, and structural skid mounting.
How do you handle electrical panels during relocation?
All panels are photographed, labeled, disconnected, wrapped in anti-static VCI film, and packed in moisture-sealed boxes with desiccants. PLCs are removed, ESD-bagged, and foam-packed.
Planning a factory move? Call BENZ at +91-98991-44488 or request a free site survey.