Plants we’ve measurably made better.
Six engagements from the last eighteen months. Numbers verified, customers anonymized at request, every component cross-linked. Not testimonials — outcomes.
$120k/yr in compressed-air savings
Plant engineering had been running the rotary-screw compressor house at 98% load for the better part of two years. The reliability team was watching loaded-hour curves climb, two of the four 200 hp units were lined up for top-end overhauls, and the capital request for a fifth compressor was already drafted at $340,000 plus install.
40% faster line changeovers with a UR cobot
Every SKU change on the variety-pack line meant 90 to 110 minutes of downtime: drain and flush, swap the change-parts kit, manually reposition the case packer guides, run a calibration loop on the labeler, and qualify the first 50 cases. Across 22 changeovers a week, that's roughly 35 hours of lost production every week — about 1,800 hours a year.
10× longer valve life on a citrus juicing line
The customer was burning through poppet-style solenoid valves on the FMC extractor finishers at an alarming clip — average mean time between failures of 38 days, sometimes as little as 26 days during peak season. Each failure took the affected extractor offline for 90 minutes, and during November–April that meant losing roughly 4,200 gallons of juice per incident at peak rates.
0.001" inspection on an aerospace fastener line
The customer's existing inspection process was a manual gauge-and-eyeball check on a 1-in-25 sample basis, with the rest going through on a process-capability assumption. Two recent customer audits flagged sampling-only inspection as a risk against the AS9100D rev D requirements being phased in.
Custom hydraulic power unit doubles block-plant uptime
The block press's original 1980s-era hydraulic power unit was running on a heavily-modified 60 hp motor with a patchwork of three different pump generations in series. Cycle time had crept up from 14 seconds nominal to 19 seconds over five years, and the system was running 25 °F over its design oil temperature, accelerating seal wear.
Cobot machine tending in a pharma fill-finish facility
The customer was facing a chronic skilled-operator shortage in a labor market where every nearby pharma site was bidding for the same people. Their downstream secondary packaging operation required four senior operators per shift to feed empty trays into a tray-erector and load filled vials into a cartoner, both at 120 trays per minute.
Every plant is a different ecosystem.
We’ve organized the case-study library by industry to help engineering and operations leaders find the work that maps closest to their environment.
Washdown-ready fluid power and flexible automation for high-throughput packaging.
Fluid-power durability against abrasive, high-chloride, around-the-clock duty.
Equipment durability through Florida heat, citrus oils, and seasonal-peak duty cycles.
Documented quality, AS9100D-aligned traceability, and the engineering rigor your customers' audits will demand.
GMP-validated automation cells with IQ/OQ/PQ documentation packages built in from kickoff.
Want a case study to look like yours?
Most of these started with a 90-minute floor walk. Tell us what's hurting most on your line and we'll come look.