EFI Group’s client, a major sugar refiner located in the U.S., had an opportunity to add a new customer, but did not have sufficient granulated sugar conveying capacity to support the required increase in output from their retail packaging machines.
EFI Group established a basis for immediate and future energy cost reduction actions for the client by linking specific processes to their respective utility costs, enabling utility costs to be treated as a controllable operational budget item versus a relatively uncontrollable fixed budget item.
EFI Group’s client manufactures plastic tubes for food products, toiletries and cosmetics. The tubes are produced in over 100 different size and shape configurations, and the process involves an injection molding step and a printing step.
Prior to working with us, our client manufactured blank tubes first and then stored them in inventory. Later, when printing plates and inks were available, the tubes were taken from inventory, printed and re-inventoried.
After careful analysis of our client’s current configuration, as well as in-depth discussions regarding their business strategy and growth goals, we realized that separate manufacturing activities were not only complicating planning processes, but also wasting valuable production and warehouse space that could potentially be used to produce additional units of their highest-profit product lines.
EFI Group proved that city meters were reading high, prompting the city to install a new meter to correct the problem. As a result, the client recovered over $700,000 in refunded fees from the city for past water bills.
Per EFI Group’s layouts, five new packaging lines, along with their associated sugar feed systems and support structures, were successfully built and installed. These lines continue to operate in a reliable manner at the specified production rates.
The design for a new drive stand arrangement reduced downtime on the primary clay extruder, ultimately decreasing maintenance costs and improving overall efficiency.