How we deliver
Our Integration Process
A repeatable, operator-first approach to turnkey packaging line delivery—built to de-risk your project, align stakeholders, and produce reliable throughput in the real world.
Four phases. One accountable partner.
Every Flowtek integration project moves through the same structured sequence—each phase building on the last, with documentation and sign-offs that carry forward through handoff.
Phase 01
Discovery & Specification
Align on product, packaging, throughput targets, and site constraints before any procurement begins.
Phase 02
Engineering & Layout
Translate specifications into a buildable plan—equipment placement, utility routing, controls, and vendor interfaces.
Phase 03
Fabrication & Procurement
Coordinate vendors, manage lead times, fabricate custom components, and sequence delivery for installation.
Phase 04
Installation & Commissioning
Execute on the floor: mechanical, electrical, utilities, operator training, and throughput validation through handoff.
Phase 01
Discovery & Specification
We start by aligning on what success looks like—product properties, packaging formats, throughput requirements, facility constraints, and compliance obligations—so every downstream decision stays grounded in agreed-upon criteria. This is where scope ambiguity gets resolved, not discovered during installation.
What we capture
- Product properties (viscosity, foaming, particulates, temperature sensitivity) and container and cap formats
- Throughput targets, OEE assumptions, uptime windows, and staffing context
- Changeover expectations, SKU strategy, and future expansion roadmap
- Site realities: available power, compressed air, floor space, drainage, access routes, and safety requirements
- Regulatory and sanitation requirements (food-grade, NFPA, explosion-proof classification, etc.)
What comes out of Discovery
- A clarified scope and risk register with open items flagged early—not at installation
- Preliminary equipment strategy covering filling, capping, conveying, labeling, and inspection
- Utility and facility planning inputs for engineering and vendor procurement
- A responsibility matrix that defines what Flowtek owns vs. what the client or other contractors own
- A clean path into layout development and detailed design
Stakeholder alignment
Define what "done right" means across engineering, operations, and procurement. Align on speed, quality targets, ergonomics, compliance constraints, serviceability, and timeline before any technical decisions are made.
Site and process review
On-site walkdown (or structured remote review) to identify facility constraints, utility availability, access limitations, and any conditions that could drive cost or schedule if surfaced late.
Specification package
Convert requirements into actionable specs for engineering, OEM vendors, utility subcontractors, and field installation teams—eliminating the ambiguity that causes rework downstream.
Phase 02
Engineering & Layout Development
We translate the specification package into a buildable integration plan—one that accounts for operator movement, maintenance access, facility quirks, and the specific interfaces between every piece of equipment on the line. Engineering isn't a handoff document; it's the coordination backbone for everything that follows.
Layout that works on the floor
Line flow, accumulation, access, and safety clearances are designed around real operator and maintenance realities—not ideal conditions.
- Equipment placement, elevations, and service and maintenance envelopes
- Conveyor strategy and accumulation planning sized to the throughput target
- Operator ergonomics, handoff points, and line-of-sight for quality checks
- Guarding, safety zone planning, and lockout/tagout access design
Utility and controls planning
Power, air, networking, and controls are coordinated during engineering—so installation is predictable and commissioning is not spent discovering gaps.
- Electrical distribution plan: transformer sizing, subpanel placement, and equipment drops
- Compressed air demand calculation, header sizing, and drop locations
- Controls architecture, I/O mapping assumptions, and safety circuit coordination
- Vendor interface documentation—mechanical, electrical, and controls handshakes across all OEMs
Phase 03
Fabrication & Procurement
A well-engineered plan only works if the right parts arrive on time, to spec, and compatible with everything else on the line. Flowtek manages procurement and fabrication as integrated activities—not handoffs—because interface problems caught here cost far less than the same problems caught during installation.
Procurement coordination
- Vendor alignment on mechanical interfaces, elevations, controls requirements, and change parts before orders are placed
- Lead-time management and delivery sequencing for predictable installation scheduling
- Shipping, receiving, and staging coordination to protect equipment and keep the project on schedule
- Spare parts strategy for ramp-up and early production stability
Fabrication for integration
- Skids, manifolds, and custom mounting structures built to the integration plan—not adapted in the field
- Guarding fabrication and site-specific mechanical adaptations
- Conveyor modifications and custom brackets for facility-specific conditions
- Build documentation that supports fast, predictable field installation
Exploring filling or process equipment?
See the liquid filling systems and process equipment we design, manufacture, and integrate into complete packaging lines.
Phase 04
Installation & Commissioning
This is where the plan becomes a line. Flowtek executes mechanical placement, all utility connections, controls integration, and a structured commissioning sequence—and we stay on-site until the line produces to agreed targets. Handoff doesn't happen until the work is complete.
Field installation
- Rigging coordination, equipment placement, anchoring, and precision line alignment
- Electrical distribution: conduit runs, subpanel terminations, and equipment drops
- Pneumatic and process utility connections, including compressed air, fluid transfer, and drain systems
- Controls integration, I/O verification, and network commissioning
- Guarding, safety device installation, and compliance documentation
Commissioning and production ramp-up
We don't leave after the first wet run. Commissioning means dialing the line in to consistently meet throughput and quality targets under real operating conditions.
- Safety and interlock verification before any product is run
- Dry runs, wet runs, fill accuracy validation, torque and labeling calibration
- Operator training and maintenance team handoff with documented settings
- Throughput stabilization and punch-list closure before final sign-off
- As-built documentation package delivered at project close-out
Safety and readiness checks
Verify guarding integrity, interlocks, emergency stops, and safe access pathways before any powered operation begins. No step is skipped to save time.
Process validation
Dial in fill accuracy, torque targets, labeling placement, coding, and inspection thresholds against the agreed specifications from Discovery. Settings are documented as they're established.
Performance verification and handoff
Confirm throughput and uptime performance against agreed targets with documented settings, operator sign-off, and a complete as-built package. The project closes when the line runs—not when the equipment is installed.
Related capabilities
The integration process is how we deliver. These pages cover what we deliver it for.
Ready to scope your project?
Tell us your product, containers, throughput target, and site constraints. We'll come back with a structured next step—not a quote for equipment you haven't specified yet.