Background
An American pulp and paper company embarked on a project to create the fastest startup converting line in company history, achieving this milestone in record time. The initiative began with transforming a used warehouse space in Florida into a fully operational converting line, a feat accomplished in just eight months. This fast-paced, schedule-driven project required close collaboration between engineering and construction teams, moving swiftly from concept to construction packages.
Approach
The client set an ambitious eight-month timeline, which was achieved and even accelerated by strategically relocating equipment from multiple locations. Because the project involved converting similar lines, installation and design were streamlined. Flexibility was a key priority, so the design incorporated swing lines, enabling simultaneous production of all products.
At the outset, the team held alignment meetings to confirm the vision, timeline, and equipment logistics, with the client providing equipment from another site. Strong collaboration among project partners ensured consistent communication and shared goals throughout the process. Despite the challenging schedule, quality standards were maintained from start to finish. The initial phase involved transforming a warehouse into a converting line, requiring building modifications and careful coordination to avoid disruptions to existing product lines.
Results
The final solution took advantage of the cost-saving benefits of the Florida location, allowing the client to strategically source raw materials. This move enabled faster execution to save time and money while maintaining flexibility to adjust production based on market fluctuations. The new facility was key to meeting consumer demand and improving production efficiency, supported by strong collaboration throughout the process.
Markets: Pulp and Paper
Services: Engineering for Product Manufacturing
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