Integrated shrink wrapping and intelligent conveyance system to improve packaging flexibility, optimize product flow, and prepare facility for future expansion
A food manufacturing client required significant modifications to an existing production line to meet updated customer packaging requirements. The facility needed to integrate a new shrink wrapping operation capable of handling a family of products with varying dimensions, packaging configurations, and throughput requirements.
The client also needed improved controls and monitoring throughout the conveyance system to reduce production interruptions caused by product jams and inconsistent flow conditions. Existing floor space limitations added another layer of complexity, as the plant planned to install additional production lines in the future and needed to maximize available manufacturing space.
To address these challenges, the client partnered with Re:Build Optimation to develop a complete fixed-bid design and build solution capable of integrating the new packaging equipment while improving overall line reliability and flexibility.
Re:Build Optimation began the project with an in-depth investigation of the existing production process, packaging requirements, and facility constraints. The engineering team evaluated product dimensions, production rates, accumulation requirements, and available installation space to determine the most effective system layout and equipment strategy.
Because a single shrink wrapper would be required to process multiple product types, extensive research was conducted to identify equipment capable of accommodating varying package sizes while maintaining the required production throughput. Multiple wrapper configurations and vendor offerings were reviewed to ensure the selected solution provided both flexibility and long-term reliability.
In parallel, Re:Build Optimation analyzed the existing conveyor system and product flow characteristics to identify opportunities for improved accumulation, jam prevention, and floor space optimization. The project team collaborated closely with plant personnel to develop a phased implementation strategy that minimized disruption to ongoing production while allowing for future facility expansion.
Re:Build Optimation delivered a fully integrated shrink wrapping and conveyance solution designed to optimize packaging performance, improve product handling reliability, and support future manufacturing growth.
Key project upgrades included:
The completed system provided intelligent product flow management while maintaining consistent throughput to the shrink wrapper, reducing operator intervention and minimizing the risk of downtime caused by conveyor congestion or product accumulation.
Re:Build Optimation successfully completed the project within a 30-week timeline, delivering a modernized packaging and conveyance system that improved operational efficiency and production flexibility.
The upgraded system enabled the client to meet updated customer packaging requirements while maintaining reliable production throughput across multiple product configurations. Enhanced conveyor controls and active jam detection significantly reduced the risk of line stoppages and improved overall process visibility for plant operators.
By relocating portions of the conveyor system overhead, the project also created valuable floor space that positioned the facility for future production line additions and long-term operational growth.
The modernization included:
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