East Coast Facility Build & Packaging Line Commissioning
A liquid product manufacturer establishing a new East Coast production facility partnered with Flowtek to define production capability, coordinate multi-OEM equipment procurement, build utility infrastructure, and commission multiple packaging lines to a fixed go-live date.
Executive Overview
The client needed a greenfield facility operational within a fixed timeline. The challenge required integration leadership across production capability definition, equipment procurement from multiple OEMs, facility infrastructure buildout, and compressed-schedule commissioning. Flowtek served as prime integration partner, translating production requirements into a complete, operational facility.
- Greenfield facility (not a retrofit or relocation)
- Multiple packaging lines across product categories
- Equipment sourced from multiple OEMs; Flowtek as integration owner
- Complete electrical and utility infrastructure buildout
- On-time facility go-live to meet business demand
- Full operational documentation at handoff
Production Capability Definition
Before any equipment specifications were written, Flowtek worked with client operations and engineering to define production targets, line architecture, and facility capacity requirements.
- Throughput targets defined by product category and market demand
- SKU mix analysis to determine line flexibility and equipment level
- Container and closure specifications cataloged
- Line count and capacity determined by production road map
- Utility requirements calculated (electrical, compressed air, water, waste)
- Layout designed for material flow, operator efficiency, and future expansion
Multi-OEM Equipment Coordination
No single OEM provides complete packaging line solutions. Flowtek managed RFQ, specification, procurement, and pre-delivery coordination across multiple equipment suppliers to ensure interface compatibility at installation.
- Equipment specifications developed for fill, cap, labeling, and end-of-line systems
- RFQ and vendor selection across multiple OEMs
- Interface specifications provided to each OEM (electrical, pneumatic, mechanical)
- Factory acceptance testing (FAT) participation and approval
- Delivery sequencing coordinated to match installation schedule
- Pre-delivery inspections and damage assessment
Facility Infrastructure Build
Electrical, pneumatic, and utility systems had to be in place before equipment installation could begin. Flowtek coordinated design and execution in parallel with equipment delivery.
Electrical Distribution
- Main service and transformer sizing for total facility load
- Subpanel design and placement for equipment distribution
- Power drop runs (50+ individual circuits) to equipment locations
- Grounding and bonding per code requirements
- Permits, inspection, and approval at each phase
Compressed Air & Utilities
- Compressor sizing for peak demand across all lines
- Air receiver tank and drying systems
- Main air line distribution with isolation and drain points
- Plant water and drain systems to support cleaning and waste management
- Natural gas and steam lines where required for specific equipment
Installation & Commissioning
With infrastructure in place, equipment was staged and installed in a phased sequence designed to meet the go-live deadline without sacrificing quality.
- Phased equipment installation (Line 1, then Line 2, etc.) to maintain schedule
- Mechanical assembly, alignment, and safety checks
- Electrical hookup and control system configuration
- Factory rep participation during initial startup and calibration
- Line-specific commissioning to target throughput
- Integration commissioning (material flow across all systems)
- Production trial runs with quality validation
- Operator training and certification
Operational Outcomes
- On-time facility go-live; no production delay
- All lines commissioned to agreed throughput targets on first attempt
- Complete documentation package delivered (electrical, equipment, procedures, manuals)
- Operators trained and confident in daily operation
- Maintenance team prepared for troubleshooting and preventive care
- Client able to onboard customers and scale production immediately
Managing Timeline Risk
Greenfield buildouts are inherently risky. Subsurface conditions, permit delays, equipment lead times, and manufacturing rework can all jeopardize a fixed go-live date. Flowtek managed risk through staged reviews, contingency planning, and proactive supplier communication. Backup equipment options were identified. Early equipment orders were placed with penalty clauses. Construction was sequenced to front-load critical infrastructure. The result was on-time facility startup with no compromise on quality or safety.
Planning a Greenfield Facility Buildout?
Share your production targets, timeline, and facility location. We'll develop a comprehensive integration plan and manage procurement through commissioning.