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Forsyths

  

 

CASE STUDY: Island Engineering Excellence IDI Services Delivers Complex Still Installation for Portintruan Distillery

Client Profile

Forsyths of Rothes, Scotland’s premier manufacturer of copper distillation equipment with over 175 years of heritage, required the installation of new copper stills and condensers at the Portintruan Distillery on the Isle of Islay. As one of the world’s leading stillmakers, serving the global whisky industry with hand-crafted copper vessels, Forsyths needed a lifting and installation partner capable of handling these valuable, delicate assets in a challenging, remote island environment while maintaining the exacting standards required for world-class whisky production.

The Challenge

The project presented multiple complex challenges that demanded IDI Services’ specialised expertise:

  • The Isle of Islay location created significant logistical complexities, requiring coordination with ferry schedules and weather windows for transporting multi-tonne copper vessels
  • Each hand-beaten copper still from Forsyths represented both a substantial financial investment and an irreplaceable work of craftsmanship, requiring meticulous handling to prevent any damage.
  • The installation site was within an active construction environment, necessitating careful coordination with multiple contractors and precise scheduling.
  • Distillation equipment requires millimetre-perfect positioning and alignment to ensure optimal whisky production quality.
  • Multi-level stillhouse configuration demanded complex rigging solutions and structural integration with the building’s steel framework
  • Coastal exposure introduced wind and environmental factors that affected both lifting operations and equipment protection
  • Project timelines were critical to maintain the distillery’s commissioning schedule.

The Solution

IDI Services designed a comprehensive installation solution leveraging our 45+ years of industry experience:

Phase 1: Site Assessment and Planning Our team conducted detailed site surveys of the Portintruan facility, documenting access routes, lifting points, structural supports, and installation sequences. Working closely with Forsyths’ technical specialists, we developed comprehensive rigging plans that accounted for each vessel’s weight distribution, structural characteristics, and connection requirements. Advanced planning addressed the unique challenges of the island location and active construction site.

Phase 2: Logistics Coordination IDI Services managed all aspects of transport logistics to Islay, coordinating with ferry operators and monitoring weather conditions to ensure safe passage of the copper vessels. Our team secured specialized heavy-lifting equipment capable of maneuvering large copper stills through confined spaces and positioning them with precision. All necessary permits and safety protocols were established prior to mobilization.

Phase 3: Precision Installation The installation was executed in carefully choreographed phases. Our experienced crews positioned the main copper pot stills on their elevated platforms, achieving precise alignment critical for distillation performance. Each lift operation was supervised by qualified personnel using proven techniques to protect the hand-crafted copper surfaces. The condensers were then integrated to create a complete distillation system, with all connections verified against Forsyths’ specifications.

Phase 4: Integration and Commissioning Support Throughout the installation, IDI Services maintained constant communication with both Forsyths’ representatives and the construction management team. Our work was carefully sequenced to minimize disruption to other contractors while ensuring structural mounting points were properly utilized. Final positioning verification ensured all equipment met the exacting tolerances required for successful commissioning.

The Results

  • Zero safety incidents throughout the entire installation operation
  • On-time delivery despite challenging island logistics and weather conditions
  • No damage to high-value copper stills or condensers during any phase of handling or installation
  • Achievement of millimetre-perfect positioning for all distillation equipment
  • Complete compliance with Forsyths’ quality control requirements and technical specifications
  • Seamless coordination within a multi-contractor construction environment

Client Testimonial

“IDI Services demonstrated exceptional capability in managing this complex installation. Their understanding of both the technical requirements and the craftsmanship embodied in our copper stills ensured flawless execution. The team’s ability to coordinate island logistics while maintaining our exacting standards gave us complete confidence. The installation at Portintruan showcases what can be achieved when specialised expertise meets meticulous planning.”

— Technical Director, Forsyths of Rothes

The IDI Advantage

This successful project exemplifies IDI Services’ core strengths in the distillery sector: comprehensive project planning, specialised heavy-lifting capabilities, experienced personnel with respect for traditional craftsmanship, and meticulous execution in challenging environments. By providing end-to-end project management from initial assessment through final commissioning support, while maintaining our unwavering commitment to safety and quality, we delivered exactly what Forsyths required—certainty in an operation where the client’s reputation and their customer’s investment were at stake.

Our ability to handle delicate, high-value equipment in remote locations positions IDI Services as the trusted partner for Scotland’s whisky industry and beyond.

For more information on how IDI Services can support your complex installation and lifting requirements, contact our team today.