SUCCESS STORY
Fully Refurbished, Tailored Standup Pouch HFFS BaggerCO-MANUFACTURER TURNS TO SIGMA FOR FAST-TRACKED HFFS BAGGER SOLUTION
A Michigan-based co-manufacturer needed to quickly scale production to meet a major retail commitment for a new granola product. The packaging required a stand-up pouch with zipper and nitrogen flush capabilities, running at 25 bags per minute. The problem? A new bagger from the OEM would take 12–14 months to deliver — at nearly double the cost of a pre-owned solution.
SIGMA stepped in with a faster, more cost-effective alternative, a pre-owned FL Tecnics Standup Pouch HFFS Bagger already in stock. See how SIGMA’s Inventory Improvement Program and expert in-house engineering brought the bagger back to like-new condition and tailored it to meet the client’s exact specifications.
The Challenge
LONG OEM LEAD TIME AND HIGH COST OF NEW
The client was under pressure to deliver their new product line quickly, but the OEM’s 12–14 month lead time threatened to derail their timeline. On top of that, the cost of buying new was nearly twice that of a used option.
COMMUNICATION HURDLES WITH OVERSEAS OEM
The client initially worked with an overseas OEM but faced delays and communication inefficiencies, making it difficult to get timely responses and move the project forward.
CONDITION AND CUSTOMIZATION OF USED EQUIPMENT
While a used unit could eliminate some of the wait, the available bagger in SIGMA’s inventory wasn’t production-ready. It required significant upgrades to meet both industry standards and the client’s packaging requirements.
The solution
A FASTER, MORE AFFORDABLE ALTERNATIVE
SIGMA Integration proposed the alternative of using a pre-owned FL Tecnics Standup Pouch HFFS Bagger already on hand. This slashed the lead time to under 7 months — well ahead of the OEM’s estimate — and cut costs by nearly 50%.
EXPERT ENGINEERING AND CUSTOMIZATION
Through our Inventory Improvement Program and expert in-house engineering, SIGMA restored the equipment to industry standards, replacing critical components and integrating essential features like a nitrogen flush system, zipper applicator, and a custom discharge conveyor. The result was a fully revitalized and customized solution, precisely aligned with the client’s production needs.
CLEAR COMMUNICATION AND COLLABORATION
Located in the Midwest, SIGMA provided easy access for the Michigan-based client to visit, inspect progress, and collaborate with our team. This close partnership ensured real-time feedback, streamlined problem-solving, and a shared understanding of project goals — ultimately leading to a smooth and successful execution.
The RESULTS
SIGMA Integration delivered more than just a refurbished bagger. They provided a crucial component of the co-manufacturer’s new production line, all within an accelerated timeframe.
By revitalizing and customizing the pre-owned FL Tecnics Standup Pouch HFFS Bagger, SIGMA delivered a fully tailored solution that met the client’s exact packaging requirements. The project was completed in less time and at a lower cost than a new OEM system, enabling the co-manufacturer to meet their production goals and fulfill their retail commitment without compromise.
PRODUCTION RATE
25 bags per minute
TIMELINE
Under 7 months compared to 12-14 months from OEM
SIGNIFICANT SAVINGS
Nearly 50% less than new machine
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