The Client faced a critical inflection point in its packaging operations. Their aging Varioline packer had become a constraint to both reliability and growth, limiting their ability to efficiently manage multiple packaging formats and integrate seamlessly with downstream inspection and palletizing systems. They required a modern, flexible solution that could handle both cans and bottles while navigating tight spatial constraints, power and air distribution limitations, and the need to maintain continuous operations. The challenge was not only technical—it was operational, financial, and strategic, demanding a clear pathway to modernization with minimal disruption to an active packaging environment.
First Key addressed the challenge through a disciplined engineering approach that combined technical rigor with pragmatic execution. The team conducted a detailed site survey, developed scaled CAD layouts, and produced a first order capital budget to frame investment decisions. The solution package included full decommissioning of the obsolete packer, integration of a new GPI packer and tray packer, and installation of an S Grip lowerator with upstream air rinsing. First Key redesigned conveyance systems, including loose bypass flow, and delivered a comprehensive rigging and installation plan aligned with space, safety, and operator workflow. This structured, phased approach enabled the Client to rapidly align internal stakeholders and move toward implementation with confidence.
The modernization enabled unified can and bottle handling, reducing changeover complexity and improving end of line reliability. Enhanced conveyance design reduced congestion, unlocking smoother flow to inspection and palletizing. Operator ergonomics and safety improved through optimized layouts and dedicated power and air distribution. The Client gained a clear, actionable capital plan supported by engineering grade layouts and budget modeling, accelerating internal approvals and shortening time to execution. The solutions identified new opportunities to increase throughput, reduce downtime, and position the operation for scalable, format flexible growth.
