A leading U.S.-based craft brewery faced the pivotal challenge of determining whether to overhaul existing conveyor systems or invest in new ones. Complicating the decision, several key packaging components, previously designed and purchased from another firm, had remained unused on the production floor for over two years. The Client needed a solution that would optimize production capabilities, minimize risk, and support future growth, all within a tight year-end delivery timeline.
Leveraging project management fundamentals, First Key conducted a comprehensive bid comparison, evaluating the two scenarios of refurbishing the existing conveyor versus purchasing new systems. Our analysis revealed that new conveyoring offered a lower risk profile and comparable costs to refurbishment. During the design phase, we identified that the existing conveyor’s excessive back pressure rendered it unsuitable for cans, further supporting the case for new equipment. First Key managed the integration of owner-furnished and pre-owned assets, engineered new conveyor layouts, and oversaw installation and commissioning, ensuring seamless alignment with the Client’s operational goals.
The results were immediate and measurable. The newly integrated tray/shrink packer achieved an efficiency rate exceeding 98%, launching without operational issues and delivering capabilities previously unavailable to the Client. These upgrades drove material and time savings, increased production versatility, and positioned the Client for scalable growth. The project not only modernized packaging operations but also unlocked new business opportunities—enabling the Client to expand product variety and leverage existing assets for long-term value creation.
