Case Studies
Integration isn’t a slide deck. It’s execution inside live production environments—under schedule pressure, compliance oversight, and uptime requirements. These case studies show how Flowtek scopes, builds, integrates, commissions, and supports liquid packaging operations, including integration ownership, process systems, packaging equipment, and the electrical/utility infrastructure that makes performance sustainable.
Published Case Studies
Some projects are anonymized by request. Where client names can’t be shown, scope, constraints, and outcomes are documented in full.
National CPG Facility Relocation & 400% Capacity Expansion
Multi-phase execution for a national CPG manufacturer—relocation of active lines into a new facility while simultaneously designing and building new automated production capacity.
Scope & Execution
- Large-scale facility relocation executed in overlapping phases under a drop-dead deadline
- Staggered line moves with same-day go-live to minimize downtime
- New electrical room, power distribution, step-down transformers, subpanels, and drops
- Compressed air infrastructure and segmented utilities for specific production areas
- Commissioning, ramp-to-rate support, and operator training
Outcomes
- 400% total capacity increase
- Labor per shift reduced (110 → 65)
- Changeover time reduced by 50%
- Higher weekly throughput within 3 weeks of go-live
- Zero safety incidents during live production execution
80,000-Gallon Tank Farm & High-Speed Edible Oils Packaging Integration
Facility retrofit and hygienic production buildout including bulk storage tank farm, routing architecture, and integration of high-speed packaging lines under city and health department oversight.
Scope & Execution
- 80,000-gallon bulk storage, routing, and sanitary transfer systems
- Integration of three high-speed packaging lines
- Full electrical distribution + pneumatic architecture buildout
- Enclosed hygienic production environment / clean-room buildout
- City, Building & Safety, and Health Department coordination
- ANSI, NSF, and UL compliance pathway
Integration Model & Outcomes
- Flowtek Process Systems — bulk storage & routing
- Flowtek Liquid Filling Systems — packaging equipment
- Flowtek North America — overall integration ownership
- Certified, compliant production environment
- Stable high-speed throughput at launch
- Infrastructure ready for additional line expansion
High-Mix Chemicals Packaging Integration & Rapid Capacity Expansion
Flexible line architecture for a high-SKU chemicals producer, integrated inside an active production environment under compressed demand timelines.
Scope & Execution
- High-SKU production environment (100+ SKUs)
- Overflow and piston filling; fully automatic line architecture
- Zero-downtime labeling, shrink wrap, case sealing, accumulation
- Chemical-compatible infrastructure; changeover-ready connections
- Electrical distribution upgrades + compressed air routing
Outcomes
- Rapid increase in available packaging capacity
- Improved changeover efficiency across SKU variations
- Stabilized throughput during demand spikes
- EW-PM sustainment program and on-call technical support
More Projects
Projects across contract manufacturing, facility buildouts, and process infrastructure—each demonstrating Flowtek's integration approach in a different operating context.
Multi-Year Automation Scale-Up — Contract Manufacturing
Supported a contract manufacturer new to automation by defining requirements, installing packaging lines, and providing sustained training and operational support through scaling.
- Requirements definition + line architecture
- Installation coordination across OEMs
- Training + sustained performance support
Temporary Production Capacity & Co-Manufacturing Support
Deployed equipment, technical labor, and operational leadership to stand up additional liquid packaging capacity quickly—without forcing permanent capital commitments.
- Rapid deployment under near-term demand pressure
- Scalable operations + experienced on-site leadership
- Stabilized output while long-term plans were executed
East Coast Facility Build & Commissioning
Defined production capability for a new facility, coordinated equipment across multiple OEMs, and executed installation and commissioning for an integration-ready packaging operation.
Tank Farms, Fluid Paths & Containment
Delivered reinforced foundations, secondary containment, stainless fluid paths, and routing architectures designed for serviceability, clean transfer, and integration with downstream packaging lines.
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