The Challenge

A major logistics operator had outgrown their 1990s-era warehouse in the North West. The facility suffered from poor layout efficiency, outdated M&E systems, inadequate lighting, and a lack of modern fire suppression. Throughput had plateaued, and the client faced a choice between relocating entirely or investing in a comprehensive transformation of the existing asset.

Our Solution

FcMig delivered a phased refurbishment programme that kept the facility operational throughout. Works included a complete mezzanine installation, new LED lighting with daylight harvesting, HVAC replacement, upgraded fire suppression, new dock levellers, and a reconfigured layout optimised for modern pick-and-pack operations. We also installed a building management system for centralised control.

The Results

30% increase in throughput achieved through optimised layout and improved material flow. £200,000 in annual energy savings delivered through LED lighting, efficient HVAC, and BMS-controlled systems. The project was completed on programme and within budget, with zero lost-time incidents recorded across the entire works period.

Client Feedback

“FcMig transformed our ageing warehouse into a facility that genuinely competes with new-build operations. The phased approach meant we never had to stop trading, and the energy savings alone have made the investment worthwhile.”

— Operations Director, National Logistics Provider

The Challenge

A national parcel carrier operating eight sorting and distribution facilities was experiencing high levels of reactive maintenance, unpredictable equipment failures, and escalating repair costs. Critical systems including conveyor drives, HVAC units, and dock equipment were failing without warning, causing operational disruptions and missed service targets.

Our Solution

FcMig deployed an IoT sensor network across all eight facilities, monitoring vibration, temperature, energy consumption, and operating patterns on over 200 critical assets. Data feeds into our AI-powered analytics platform, which identifies anomalies and predicts failures before they occur. We integrated the system with a centralised dashboard for the client’s facilities team and established automated work-order generation.

The Results

45% reduction in reactive callouts within the first twelve months of operation. 99.8% uptime achieved across all eight facilities, up from 96.2% prior to implementation. Annual maintenance expenditure reduced by 22%, and the client now has full visibility of asset condition and remaining useful life across their entire estate.

Client Feedback

“The shift from reactive to predictive maintenance has been transformational. We no longer dread Monday morning breakdowns. FcMig’s system gives us confidence that our facilities will perform when we need them most.”

— Head of Property, National Parcel Carrier