In early 2006, Fives Solios, namely Solios Thermal, was selected as a key cast house supplier by a major aluminium producer for a new 130,000te/yr re-melting facility. The project scope included not only the supply of modern melting and holding furnaces plus ancillary equipment, but also pre-heating furnaces, an air pollution control system, basic cast house engineering, cooling water schemes and complete turnkey project management. This project presented particular technical and logistical challenges and was required to meet exacting European environmental / efficiency standards for all major contractors involved. The facility was commissioned in March 2008 and the first production was on schedule. This paper will discuss the challenges that the Solios Thermal project team had to overcome, from layout of equipment to conclusion of the project; also how good communication and close collaboration between the customer and all major subcontractors resulted in a successfully implemented plant.