Race against time to the Middle East

When a refinery’s operational continuity is at risk, time ceases to be a mere logistical variable and becomes an economic one.

This was precisely the scenario that unfolded when an extraction site in the Middle East required the immediate dispatch of a new heat exchanger to prevent a complete production shutdown.

From the outset, the operation presented Transmec Group’s Project Cargo division with a critical challenge: the unit’s physical characteristics. At 20 tonnes and 6.50 metres long, 2.50 metres wide, and 3.60 metres high, the heat exchanger required going far beyond standard shipping methods.

With sea freight completely out of the question due to excessively long lead times, the division devised a bespoke air freight solution, booking one of the few aircraft in the world capable of handling such a payload: an Antonov An-124-100M cargo plane.

As the clock kept ticking, the logistical machine swung into action along the corridor connecting Italy to the Middle East. Urgent heavy haulage by road delivered the exchanger to Rome Fiumicino Airport, where it was immediately handed over for rigorous security inspections and routine molecular checks. Every minute of this phase was integrated with pinpoint precision into airport operations, working around the clock to eliminate waiting times.

To ensure that a 20-tonne giant could undergo a transcontinental flight in total safety, the loading procedures were managed like a high-end engineering site. Using a combination of high-capacity cranes and dedicated ramps, the component was secured onto a special metal frame with reinforced lashing points, custom-designed to balance weight distribution within the Antonov’s cargo hold.

As Domenico Longano, Air & Ocean Project Division Manager at Transmec Group, highlighted:

“It was an extraordinarily delicate operation, complex not only due to the scale of the component, but above all because of the imperative need to execute it within extremely tight deadlines.

“A challenge of this magnitude required high-level specialised planning and the use of ad hoc equipment; decisive factors that enabled us to eliminate downtime risks and safeguard our client’s operational continuity.”

Take-off from Fiumicino marked the definitive transition from emergency to resolution. An operational success achieved thanks to the direction of Project Supervisor Christian Randazzo, supported by Transmec Group’s Air Division. Delivered to its destination precisely within the agreed timeframe, the exchanger was immediately integrated into the facility, allowing the refinery to maintain full production capacity.

A special thank you goes to all parties involved who, through their professionalism, collaboration, and dedication, played a decisive role in the success of this operation.