Expansion at Scale — Seamless IT Relocation and Modernisation for a UK Manufacturer
LeapIT orchestrated the full-scale technology move and upgrade for a large plastic manufacturing business in Stechford, Birmingham. In just six hours of planned downtime, the business was successfully relocated to a new factory, with modernised infrastructure, enhanced cyber security, and major cost efficiencies.
6 Hours
Downtime
60+
Staff Supported
100%
Systems Replaced
The Challenge
The client faced a high-risk factory relocation with no room for extended downtime. Their entire IT estate — including servers, networks, security, and communications — needed to be replaced and operational in a single day. The move also provided an opportunity to modernise legacy systems and reduce power usage.
Key challenges included:
- Outdated IT and telecoms infrastructure (servers 8+ years old, phones 18 years old)
- Large, distributed factory layout with multiple data cabinets and fibre connections
- Non-cloud setup requiring on-premise solutions
- Business continuity was critical: "Time is money" in a high-output manufacturing environment
Our Solution
LeapIT was brought in six months ahead to lead the full technical strategy and execution of the move. Services included:
- Cyber Security – Upgraded server security, made systems Cyber Essentials ready
- Cloud Support – Hybrid server upgrade with optimised on-prem setup
- Communications – Brand new VoIP phone system, tailored to staff mobility
- Printer & Copier Solutions – Streamlined print infrastructure
- Consultancy – Full project management, supplier coordination, and strategic planning
LeapIT pre-installed infrastructure (Wi-Fi, cabling, switches, phones) at the new site to minimise downtime.
Technology & Approach
Core Platforms: On-prem servers with upgraded security; new VoIP solution
Support Model: Onsite-led project with remote monitoring post-move
Approach:
- Pre-implementation audits
- Collaboration with contractors
- Seamless server upgrade during the move
- Full system testing and documentation
- Security hardening in line with Cyber Essentials
The Results
Implementation & Delivery
Project Phases: Audit → Infrastructure Planning → Pre-Staging → One-Day Move → Testing & Go-Live
LeapIT's strategy enabled a 6-hour switchover, avoiding costly downtime. The most complex task — upgrading servers while relocating — was achieved through a unique migration technique that kept business disruption minimal.
"LeapIT handled our factory move flawlessly. They took complete ownership of our tech estate and delivered a seamless transition, with minimal downtime and major savings. The team were proactive, reliable, and a true partner throughout."
Operations Director
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