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Modernization of a High Volume Consumer Product Bottle Packaging Line

Modernization of a High Volume Consumer Product Bottle Packaging Line


A key Fortune 50 client required modernization of a high volume packaging line for their highest demand product. This Production Line is also the highest profit generating line in the business unit. The purpose of the modernization project is to integrate new equipment for meeting new regulatory requirements and for new packaging configurations to meet market place needs. Due to the production value of this line, the execution of the project required precision to meet critical scheduling and minimize any downtime. The scope of work included upgrading of the system’s overall control, inspection/reject tracking and operator interface systems with current technologies.

This key client engaged Foth to review and evaluate the line’s overall performance and operation. Foth was then engaged to develop conceptual system architecture, a project master plan, and budgetary costs to implement the project. Based on those appropriation grade documents, projects were approved and funding secured to implement all identified upgrades creating a $10 million program/project.


Foth was responsible for developing an efficient line layout to maximize throughput and developing the plant’s first major platform change to Control Logix PLC and new safety technology. Included in Foth’s responsibilities was the coordination and total integration of major equipment vendors from Europe who were required to standardize their PLC, Safety, HMI and VFD platforms to conform to the client’s standards. Foth provided construction/installation documentation, supported the quality process for this GMP operation, provided construction management, and supported the production startup. Foth trained operators/maintenance personnel on the new technology.


The line modernization resulted in the system meeting the required quality standards, increased productivity and operational efficiency, higher production speeds, and capabilities to produce new packaging configurations. The new control and safety system architecture allowed for improved systems maintenance and reduced capital costs by minimizing electrical wiring to I/O and VFD drives.

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