Relocating 7 precision laser cutters for Wentworth Wooden Puzzles

Based in the heart of the Wiltshire countryside, Wentworth Wooden Puzzles is renowned for its intricately crafted wooden jigsaw puzzles, each cut and finished using a fleet of highly specialised laser cutting equipment.

Over the years, as their business has continued to grow, Wentworth found themselves outgrowing their existing facility, a repurposed dairy farm in Malmesbury. 

And with operations stretched across a network of separate sheds and outdated infrastructure, the team decided it was time to relocate to a more spacious, purpose-built facility in Swindon.

To ensure a seamless transition, they needed a trusted partner to help them safely and efficiently move seven bespoke laser cutting systems, plus ancillary equipment, from the existing facility to their new home. 

So, they came to us for help.

We were brought in to deliver a full relocation package with the scope of work. This included mechanical and electrical dismantlement, packing, move-out, transport, move-in, rebuild with new cable containment and replacement service connection, and hook-up.

One laser cutter at a time

The laser cutting systems varied in age and configuration, with the older models being fitted with welded glass laser tubes that were particularly fragile and sensitive to vibration and impact. 

Due to ongoing manufacturing requirements, each laser cutting machine had to be relocated and proven operational before relocation of another was possible.

All the while, moving efficiently to ensure production downtime was kept to an absolute minimum.

Planning, marking, moving

We began the project with a detailed site survey, working closely with Tom, Wentworth’s technical and facilities operations manager. 

Together, we identified potential equipment-specific challenges, reviewed access routes, and assessed each preferred lifting method and associated rigging equipment required on a tool-by-tool basis.

Tom proactively shared a proposed phasing plan, which we used as a baseline for scheduling engineers and logistics. His input, based on his deep understanding of the equipment, was instrumental in shaping a smooth, achievable delivery programme.

We then started on disassembly, match-marking every component to simplify the reassembly process at the new site. This included measuring up, affixing labels to each part, photographing the disassembly, and recording all technical details.

Move-out required a bit of creativity.

The equipment was particularly large and heavy (measuring 2.5 x 2.5 square meters and weighing around three tons). And due to the high sensitivity of the internal components, each unit had to remain level throughout removal.

But a steep access ramp leading out of the original production hall made the move-out especially challenging. 

Our solution involved partially lifting each laser cutter at the lead end using a forklift, while the tail end remained supported on machine skates. This allowed us to carefully guide the unit out of the building and down the steep ramp, with the forklift controlling the lead end height and maintaining a level orientation throughout.

Once the tail end reached the door threshold, the equipment was set onto blocks and rigged for lifting. We then transferred it onto a flatbed lorry using a HIAB crane, ensuring level positioning throughout the entire manoeuvre.

Handled with care

Transporting the newer laser cutting systems presented a logistical challenge: Their large size ruled out curtain-sided lorries. So we decided to use flatbeds and low loaders to transport them. 

To ensure safe transit, we secured each unit with heavy-duty banding and straps. We kept tarpaulins on standby, but dry, calm weather conditions allowed us to proceed without them, saving valuable time.

Once on-site in Swindon, we offloaded and reassembled each piece of equipment with the same engineering team that had performed the dismantling. This continuity proved vital, ensuring in-depth familiarity with each piece of equipment’s configuration and speeding up the troubleshooting process.

Beyond reassembly, we also delivered a full mechanical and electrical installation package. This included cutting and fixing cable containment, replacing electrical power cables and fixing new exhaust ducting.

The outcome was a smooth, efficient installation and a fully operational production line. And delivered faster than the original schedule anticipated.

Happy client, happy team

The success of this project was built on a foundation of careful planning, collaborative delivery, and consistent engineering oversight. 

Maintaining the same team throughout helped ensure technical integrity, accountability, and a clear line of communication from start to finish.

We’d like to extend a special thanks to Tom Finch at Wentworth for his involvement and support. His wealth of technical insight and hands-on approach played a major role in the smooth progression of each project phase.

Here’s what Tom had to say about working with us:

“Excellent from start to finish! A great team of professional engineers who did an amazing job on a complex project.”

Need an expert to support your equipment relocation project?

We’ve supported OEMs and end users to move and install high-value capital equipment for more than three decades.

Head to our equipment relocations service page to find out more.