SunPine's new factory is ready to deliver

Strong teamwork built SunPine's new factory

A year ago, the time had come. A completely new factory began construction next to the existing one, and the challenge was not to disrupt ongoing production. Today, the factory is ready to deliver sustainable tall oil diesel and contribute to Sweden's continued green transition. The secret? A really strong team effort.

– It has been a project with fantastic teamwork, says Ulrika Hagman, project manager for investments at SunPine.

Building a completely new factory is a complex task. It requires careful coordination and streamlining of the work. Furthermore, building a new factory next to a facility that is already in full operation – without disrupting transportation and everyday operations – is an even more complex task.

– It's a matter of being a bit like a choreographer and planning everything down to the smallest detail, from what can be built to when different vehicles can pass through narrow passages, says David Öquist, CEO of SunPine, and continues:

– These are no small challenges that the project team has had to deal with. In addition, we had to deal with a delayed environmental permit, winter construction and a global pandemic. Despite this, we now have a completely new factory in place. It's incredibly good work by everyone involved.

Mild winter facilitated construction

Ulrika Hagman, project manager for investments, and Andreas Bäckström, start-up manager, have been ultimately responsible for the project with the new factory. The plan was to start construction in April–May to have favorable weather conditions during construction. But the environmental permit that was required was appealed, the months passed and autumn began to approach.

– We were a little worried about the cold and the amount of snow that could come. It could be bitterly cold here and several decimeters of snow could fall in a day, says Andreas, and Ulrika adds:

– And because the factory is built in an open frame, which means that the facility lacks walls and roof, the weather and wind have a direct impact.

Handling certain materials, such as steel and cables, can also be difficult in very cold weather. But even though the plan was to build during the summer months, the team had thought about choosing materials that could handle the cold.

– It was wise that we took that into account when we now had to build everything in the cold and snow, says Ulrika and Andreas adds:

– And even though the first winter storm hit just when we were about to get our largest parts in place, the rest of the winter was unexpectedly mild, which was very good for us.

A logistical feat

One of the biggest challenges of the construction, but also one of the biggest achievements, was building a new factory next to an existing one. Scaffolding, cranes, machinery and construction workers needed space to operate – without disrupting ongoing production. In addition, the factories had to be built together for a start-up, which resulted in the creation of a completely new model for the new facility.

– The challenge was to connect to existing parts that are already in operation. We had to expand certain parts to be able to supply and receive the new factory flows, says Andreas, and Ulrika adds:

– It required advanced logistics planning to be able to handle all the transport and at the same time get in cranes and equipment for the parts that were needed. But, we managed to do that.

Quick problem solving moved the project forward during the pandemic

Just like the rest of society, the factory construction was also affected by the Corona pandemic. The workplace was adapted in several ways to make it easier for staff to keep their distance. Among other things, more barracks were built and a schedule for coffee and lunch breaks was developed. Italy, which was badly affected by the virus from the start, closed down, which resulted in the Italian team being stuck in the country.

– We received reports that the factory was shut down, and since we had procured an Italian boiler, we were a little nervous. We were lucky, however, because they just had time to send the boiler before they shut down. However, there were problems with the infrastructure because a bridge had collapsed outside Genoa, says Ulrika and continues:
– And not only that, the Italian team that was supposed to install the pipes got stuck in Italy due to the travel restrictions. So we had to rethink, and arranged for a Swedish contractor to install the pipes and for the Italian team to come at a later time to inspect the work. I think we have solved everything along the way in a very impressive way. Despite the pandemic, we have managed to keep to the schedule, says Ulrika.

“We would like to thank the entire team for making the start-up go so well”

The start-up of the new factory has followed a detailed plan where step by step everything has been ensured to function as it should. Both the parts of the new facility, but also the connections where the two facilities will be joined.

– We made an extremely detailed and meticulous start-up plan for the launch. And we had a special team that worked focused on that plan, says Ulrika and Andreas fills in:

– We had people from all departments on the startup team, which meant we could work closely with all skills. It was a very successful concept, and we would like to thank the entire team for making the startup go so well.

Teamwork and participation

Today, the new facility is up and running and everything is working as it should. Despite challenges, both expected and unexpected, SunPine managed to get the project off the ground, right on schedule. And the secret to its success can be summed up in teamwork.

– It is valuable to be involved from the start and create a sense of participation in the organization as a whole. It is important that everyone feels included in the journey, and it feels like we have succeeded in that. We have a very nice new factory. Even better than we had imagined, says Andreas.

“I am ready for everything that lies ahead of us”

Both Andreas and Ulrika find it a bit strange that the project they worked so intensively on is now finished. At the same time, they are excitedly looking forward to new challenges together with their colleagues at SunPine.

– It will feel empty now that it is “finished”. It feels both fun and sad that we are finished, says Andreas, and Ulrika agrees:

– It has been a great journey! Intense, challenging, but above all a project with fantastic teamwork. It is sad to say “goodbye” to employees with whom we have worked so closely. However, I feel energized for everything that lies ahead of us now. And as soon as the opportunity arises, I hope for a truly festive opening of the factory, concludes Ulrika.