Created Production Capacity Model Avoiding $10M+ CAPEX Spend for PE-Owned Packaging Manufacturer

Capabilities

A private equity-owned packaging manufacturer faced growing demand requiring them to evaluate production expansion requirements.

The company needed a plan to support rapid business expansion in the Southwest with its existing manufacturing plant approaching capacity.

Evaluated existing production capacity and manufacturing footprint
Developed SKU level capacity model by production asset and geographic region to include production transfers, customer wins, and expected sales growth
Identified operational excellence improvement opportunities at existing production sites
Developed business case to assess the EBITDA impact of 8 scenarios

Results

Avoided $10M+ in expected CAPEX to stand up a new plant

II.

Determined company was capable of supporting sales expansion with existing footprint through a series of plant operational improvements

III.

Reduced potential carbon footprint by 7,800 tons CO2/year by not expanding into new 190,000 sq ft manufacturing plant

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