SUCCESS STORY
shrink sleeve applicationCUSTOM BOTTLE SLEEVING SOLUTION IN 2 WEEKS
A client tasked SIGMA Integration with creating a custom bottle-sleeving solution to meet a high-demand production goal. Facing a tight two-week deadline before a crucial Site Acceptance Test, the client required a system capable of sleeving 80 bottles per minute to achieve a total of 2 million bottles within 14 days.
See how SIGMA Integration’s rapid deployment of a turnkey system, leveraging in-house resources and a tailored design, allowed the client to meet both their timeline and production requirements effectively.
The Challenge
HIGH-VOLUME DEMAND
The client secured a large co-packing contract to sleeve 2 million bottles within a tight six-week timeframe. To meet this ambitious goal, the client required a reliable and efficient sleeving system. However, they lacked the necessary equipment to fulfill the high-volume demand and needed a tailored solution to meet the target.
SHORT TIMELINE
The project had a very short timeline. After the client approved SIGMA’s proposal, there were only two weeks left before the Site Acceptance Test (SAT). With no time for delays, the system had to be designed, implemented, and tested quickly to meet the deadline.
PRODUCTION SPEED
To meet production demands, the client required the sleeving system to operate at 80 bottles per minute, running two 10-hour shifts per day with minimal workforce requirements.
The solution
CUSTOM SLEEVING SYSTEM
Leveraging its extensive in-house equipment inventory, SIGMA quickly designed and integrated a custom bottle-sleeving system to get the client up and running as quickly as possible. This system featured 11 pieces of equipment, including a new AFM Sleever capable of achieving the required production speed of 80 bottles per minute, ensuring the client could meet their operational demands.
RAPID INSTALLATION
SIGMA Integration was able to rapidly install the custom bottle-sleeving system at the client’s facility by first constructing the system in-house at SIGMA’s 50,000-square-foot shop. This approach allowed the team to pre-assemble and integrate the system, minimizing installation time at the client’s facility to just two days. By efficiently disassembling, shipping, and reintegrating the system, SIGMA ensured the client could meet their production demands on schedule, ahead of the Site Acceptance Test.
The RESULTS
After installation and reintegration, SIGMA conducted a Site Acceptance Test at the client’s facility. The rental system met the requirement of running 80 bottles per minute, enabling the client to produce 45,600 re-sleeved bottles per shift. With the sleeving system in place, the client exceeded their goal of producing 2 million bottles in 14 days. By leveraging the available equipment in their extensive in-house inventory, SIGMA completed the project within a tight two-week timeline, surpassing the client’s expectations for production throughput and quality.
Production Goal
2 million sleeved bottles in 14 days
Production Rate
80 bottles/min (45,600 bottles per shift)
Turnaround Time
2 weeks (from start to finish)
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