Industrial Packaging Plant Expansion

Expansion is a beautiful thing. It is one of the ultimate indicators of growth.

Goals are critical and income is arguably the most integral component of a business model, but you can make a valid point that goals will lead to success and high production, thus leading to growth, which is the path to increased revenue.

Since 2015, industrial manufacturing and packaging have experienced consistent growth in demand and revenue.

This uptick has lead to invaluable growth opportunities for these industries.

But now, you have to keep up with demand. Whether your facility packages products during or after the manufacturing process, you need to stay on pace with the products.

Let’s walk through a plant expansion and look at some integral steps you should take.

Determine the Extent of your Expansion

Before just leaping into expansion for your industrial packaging business, ask yourself the following questions to see where you stand.

1. Is there any way to utilize your current facility more before you expand?
2. Will expansion improve the efficiency of your packaging process and methods?
3. Can an expansion occur while still functioning and completing daily tasks?
4. Can the building you’re in now withstand ten or twenty more years of growth?
5. Would it be better to relocate to a new building rather than expand the current facility?

Knowing the answers to these questions will assist in keeping your thoughts, actions, and plans in line.

The ultimate goal, should expansion still be the desired path, is to maximize your overall packaging output and increase productivity.

If you have firmly concluded that expansion is the best direction for your industrial packaging facility, then continue reading, and we will walk you through an efficient step-by-step process.

Important note: Aside from relocation, another alternative to expansion is renovation. If you have spaces, rooms, or mezzanines that are strikingly under-utilized, consider rearranging and renovating your space for optimal functionality.

Bring Your Expansion to Life

Collect Data

Make sure you fully understand the ins and outs of your current packaging production level. Discover areas that you exceed quotas, pain points like any wasted idle time, and any potential solutions.

Gain a clear perspective on what types of products and packaging will need to be produced for the expansion and the items needed in each packaging category.

Then, consider the space that is needed for the storage of raw materials, such as pallet storage.

Finally, diagram your process flow and equipment layout. Having a detailed report or checklist regarding your processing needs will prove to be beneficial as your expansion plans move forward.

Design Moving Forward

Now that you have collected your current plant’s data, you must decide what is needed for expansion.

Storage needs and production capacity are the main focuses here. Remember, wasted space is wasted money.

You’re leaving money on the table if your industrial packaging facility isn’t optimally utilizing storage space. Consider flooring, walls, ceiling, and virtually all physical space requirements.

Conceptual Planning

It is never a bad idea to develop multiple concept plans.

Don’t pigeonhole yourself with only one path and direction. The best way to ensure that all your packaging needs are met is by comparing multiple concept plans. Discussing theoretical models with packaging designers is always a good place to start. We've found that the best way to ensure that all your packaging needs are met is by comparing multiple concept plans.

You also want your packaging manufacturing process to be in line with your business model. Meaning, if environmental impact is important to you, look into sustainable packaging solutions or reusable packaging.

Keep your attention on the following components of each concept plan:

• Ease of implementation
• Practicality
• Any potential indirect impact from the new packaging manufacturing process
• Estimated cost (including both product cost and packaging costs)

Time is certainly money, but this is a step you do not want to rush. Make sure you are satisfied with your chosen plan before continuing. 

Professional Site Review

Now is the time to review your overall master plan.

Spend the time to ensure that your final plan is agreed upon and covers all the specific details that it should. Even though your expansion is on your current site, make sure you look into codes.

Construction and expansion can lead to changes in utilities and zoning laws.

This final, master plan for your industrial packaging expansion should include the following fine details:

• Building features
• Your equipment layout
• Process flow / production lines
• Cost estimates
• Quality control
• Staff areas
• Function areas
• Utility information
• Building codes
• Zoning codes
• Design implementation
• Plans on how to handle any product returns, if necessary 
• Future expansion and growth plans

That is a long list, but the more detailed and specific you are in your review, the better the chance your expansion proceeds smoothly.

Common troubleshooting with expansion

Your industrial packaging facility will not be the first to expand, and it will not be the last. The good news is that you can learn from other company’s previous experience to ensure that your expansion is as flawless as possible.

Common issues and problems that accompany expansion include:

Poor Planning: We have tried our best to hammer this home; planning is absolutely crucial to a successful expansion. The saying leave no rock unturned applies beautifully here.

Be prepared for anything and have your expansion plans and methods in full scope. Poor planning will often result in mistakes, unpreparedness, oversights, and wasted time.

Taking On Too Much: If you have a team, get them involved. You may want to hit the ground running, and that is a good thing, but don’t bite off more than you can chew.

Getting your team involved helps them buy in and offers ideas, insight, and knowledge you would have never otherwise had. Don’t be your own project manager unless you have the necessary experience.

Choosing Poor Building Materials: You want your expansion to be as efficient and cost-effective as your packaging process. Don’t let maintenance fees or expensive materials bog down your progress.

Inflexible Design: If you are backed into a corner with your design and it does not allow you to achieve your concept plan, utilize space efficiently, or incorporate all of your equipment properly, that is a major design issue.

This should be ironed out during the concept planning, but ensure that your expansion design is flexible and speaks to your needs.

Contact CDMG Today

One feature that can assist in your packaging facility’s expansion is a Steel Building.

Steel buildings are modern, cost-effective, easily expandable and have a positive environmental impact. Their expansion walls and frames allow for growth when you need it, without adding too much overall product cost or unnecessary material consumption.

Our team can help you from planning, execution, and even offer ideas on new packaging suppliers if you need. We can show you different business model strategies to find which one works best for you.

CDMG’s steel is 90% recycled material, so you have the ability to become an environmental leader within the packaging industry.

If you’d like to learn more about how CDMG’s Metal Buildings can facilitate your expansion, click the link below today.