We got a panicked phone call from the Engineering Manager of the Cereal Division of a large multinational food processing customer. Could we help with the redesign of their cereal conveyance system? Production volume had to be stepped up by a factor of four in their packaging line - for three different products.

In order to accomplish this, the packaging feed system at the bottleneck had to be redesigned, built and installed within four weeks. Was that possible?

We stuck to our principle of understanding the work process before coming to any conclusions. Two highly qualified TRENTFAB staff were immediately dispatched to review the existing conditions; by line, by product and by conveyance system. They met with the customer's engineers to discuss the functionality and integration of a new system.

Within 24 hours of our preliminary meeting, we had a solution for achieving higher volume and speeds over a broad range of products, including eight different cereal grains.

We submitted preliminary drawings to the client for review. A price range was accepted and the project approved on a "not to exceed" basis.

We mobilized engineering, purchasing, machine shop and fabrication shop staff at our facility. While we manufactured the client's conveyance system, plans for inspection, packing, shipping and millwright crews were prepared. Additional subcontractors were assigned to handle parts of this job and shorten production time.

Once the lines were ready, redundant equipment was removed to make way for the new. Our millwrights installed the new conveyance system, then remained on site as the client tested the lines. We always ensure that the job is done right the first time. In this case we also stayed on for the sanitization process and operator training.

By adhering to our plant evaluation process, we were able to fully understand the complex production problems at the plant, then recommend and implement effective solutions. For us it's not luck. We understand how the industry works. We understand plant bottlenecks. And we know no two jobs are exactly alike. We never assume that the next project is the same as the last.

In this case, our client was deluged with details and needed someone who could understand the plant goals and look at the problem objectively. By getting involved early in seeking a solution, we were able to add value to this project.

We successfully implemented the new high speed system within four weeks. Goals were met. Packaging productivity accelerated dramatically.