High-Mix Chemicals Packaging Integration & Rapid Capacity Expansion
Integration of flexible, high-SKU packaging architecture for industrial and household chemical products, executed inside an active production environment under compressed demand timelines.
Executive Overview
A growing chemicals manufacturer required rapid capacity expansion to support increasing demand across a diverse portfolio of cleaning products, polishes, and specialty liquids. The environment demanded flexible changeovers, chemical compatibility considerations, and infrastructure capable of supporting high-throughput and high-variation production.
- High-SKU production environment (100+ SKUs)
- 16 oz – 64 oz PET containers
- Overflow and piston filling technology
- Fully automatic line architecture
- Training and ramp-to-rate with 100% new workforce
Flexible Line Architecture
The system was engineered for rapid changeovers, SKU flexibility, and stable throughput.
- Automated filling, capping, induction sealing
- Inline coding and labeling
- Dual-station labeling configuration
- Shrink wrapping and case sealing
- Accumulation systems to prevent bottlenecks
Layout planning focused on minimizing congestion while maximizing operator visibility and serviceability.
Infrastructure & Utilities
- Electrical distribution upgrades and additional drops
- Compressed air routing optimized for high-demand cycles
- Chemical-compatible fluid routing components
- Serviceable valve assemblies and changeover-ready connections
Infrastructure was designed to accommodate future line additions without major rework.
Operational Outcomes
- Rapid increase in available packaging capacity
- Improved changeover efficiency across SKU variations
- Reduced labor requirements per shift
- Stabilized throughput during demand spikes
- Enhanced serviceability and preventative maintenance access
Lifecycle Support & Sustainment
Flowtek implemented structured Extended Warranty & Preventative Maintenance (EW-PM) programs and on-call technical support to maintain throughput and minimize downtime.
- Scheduled preventative maintenance planning
- On-call technical service
- Operator retraining and onboarding support
- Performance tuning and optimization
Scaling Chemical Production?
Share your SKU count, container formats, and throughput targets. We'll define a scalable integration strategy.