Enabling Cost-Effective Manufacturing Expansion in Eastern Europe

Key takeaways

• Successfully supported the relocation of multiple production lines from Central to Eastern Europe, transforming an empty warehouse in Poland into a medical device manufacturing facility
• Deployed a specialist, high-performing team of 4 senior contractors across engineering, validation, quality, and chemistry - with the team recognised multiple times for their contribution on-site

The challenge

A global medical device manufacturer sought to expand its European operations by redeveloping an abandoned warehouse in Poland into a fully operational manufacturing facility.

The initiative was part of a wider cost optimisation strategy, requiring the relocation of several production lines from Central Europe to the new Eastern European site.

This presented several critical challenges:

• Managing a complex product transfer across multiple geographies
• Re-establishing and optimising manufacturing processes in a new facility
• Ensuring compliance with strict medical device regulatory and quality standards
• Delivering against tight project timelines within a live transformation environment

The manufacturer required specialist, on-the-ground contractors who could ensure a smooth transition without disrupting existing supply chains or compromising product quality.

The solution

EPM Scientific partnered with the company to build and deploy a dedicated product transfer team to support the end-to-end process, focusing on both technology transfer and process optimisation to ensure that manufacturing operations were not only replicated but improved in the new facility.

They provided four senior-level contractors, each addressing a critical component of the project:

• Senior Chemist – Led the redevelopment of coating processes to ensure performance and scalability
• Senior Project Engineer – Oversaw production line setup and machine qualification activities
• Senior Validation Engineer – Managed equipment qualification and validation to meet regulatory requirements
• Senior Quality Engineer – Ensured robust quality systems and compliance standards were implemented

Beyond technical delivery, the EPM Scientific team ensured strong collaboration between contractors and site leadership, enabling rapid integration and alignment with project goals.

The result

The project delivered strong results:

• Key project milestones and deadlines were successfully achieved
• Production line transfers progressed smoothly with minimal disruption
• Enhanced manufacturing processes drove greater efficiency at the new site
• The contractor team were recognised multiple times for outstanding performance, including one contractor receiving an Employee of the Month award

The collaboration has positioned the client to achieve significant cost savings while establishing a scalable manufacturing base in Poland.

Summary

By combining technical expertise with a collaborative delivery model, EPM Scientific ensured that this client’s new Polish site meets high standards of quality, efficiency, and regulatory compliance – supporting their long-term growth and cost optimisation strategy in Europe.

If your organisation needs the right experts to deliver product transfer, brownfield redevelopment, validation, quality or engineering projects, get in touch with EPM Scientific to discuss how our contract network can help keep your programme on track.