Multi-Year Automation Scale-Up — Contract Manufacturing
A contract manufacturer new to production automation partnered with Flowtek to define requirements, select and install packaging lines, and provide sustained operational support through the growth phase—delivering scaled capacity without the burden of building internal automation expertise.
Executive Overview
The client—a contract packaging facility—had grown through manual labor and semi-automated processes. Facing increased customer demand for automated contract packaging across multiple product categories, they needed a partner who could define production requirements, select OEMs, coordinate installation, and remain engaged as a technical resource through scale-up. Flowtek provided end-to-end integration and operational support, enabling the facility to transition to full automation without hiring a permanent automation team.
- Client anonymized per contract; serves CPG brands across multiple categories
- New to automation; no existing line architecture or specification standards
- Scaled from manual to fully automated packaging across multiple product types
- Multi-year project with multiple line additions
- Significant reduction in labor per shift during scale-up
- Sustained technical support through commissioning and ramp-to-production
Requirements Definition
Before any equipment was specified or procured, Flowtek worked with client operations and engineering to define the production architecture.
- Throughput requirements defined for each product category and SKU
- Container specifications and dimension ranges cataloged
- Automation level determined by volume and changeover frequency
- Line architecture designed for flexibility and future expansion
- Utility requirements (electrical, compressed air, water) calculated
- Layout and spacing planned for phased line additions
This deliberate definition phase prevented over-specification and ensured each line was right-sized for the actual production mix.
Line Installation & OEM Coordination
Flowtek managed procurement and installation across multiple OEM vendors, coordinating equipment delivery, staging, and sequenced commissioning to minimize downtime and operator learning curve.
- Vendor selection and RFQ coordination across fill, cap, labeling, and end-of-line OEMs
- Interface specifications provided to each OEM to ensure compatibility
- Pre-delivery reviews and factory testing participation
- Phased delivery and installation to minimize floor disruption
- Electrical and pneumatic integration (power drops, compressed air lines, control signals)
- Setup and calibration of each line component
Sustained Operational Support
The transition from manual to automated production is a multi-month process. Flowtek remained engaged as a technical resource through the operational ramp-up.
- Post-commissioning operator and maintenance technician training
- Shift oversight and troubleshooting during initial production runs
- Performance monitoring and bottleneck identification
- Line tuning and optimization to achieve target throughput
- Root cause analysis and corrective action for quality issues
- Ongoing support as new products and SKUs were introduced to the line
Operational Outcomes
- Transitioned from manual to fully automated packaging across multiple product categories
- Labor per shift reduced significantly during scale-up phase
- Minimized unplanned downtime through sustained technical support
- Production capacity grew with client's contract wins
- Flexibility built into line architecture allowed product mix changes with minimal reconfiguration
- Operators and technicians gained confidence and competency through hands-on support
Integration as a Strategic Service
The contract manufacturing environment demands responsiveness and flexibility. Large CPG customers expect reliable, automated production across multiple SKUs and formats. Flowtek's role as integration partner and sustained technical resource enabled the client to meet those customer demands without building a permanent in-house automation function.
"We knew automation was necessary to win bigger contracts, but we didn't have the expertise to define what we needed or coordinate multiple vendors. Flowtek didn't just install equipment—they stayed with us through the transition, trained our teams, and helped us optimize. We grew our business without building an automation team."
— Operations Director, Contract Packaging Facility
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Share your production mix, volume targets, and growth plans. We'll define the automation approach and provide integration support through commissioning and beyond.