Pasta Plant Launch on an Aggressive Schedule — Including Category 3 Safety
A new packaging line, a new pasta kitchen, two sauce kitchens, a Category 3 safety system, and a hard product-launch date. Delivered on time, under budget, with 24/7 remote support after handoff.
A major food manufacturer was launching a new product, and the launch date was the critical path. To hit it they needed automation and controls for a new packaging line, a new pasta kitchen, a new sauce kitchen, and upgrades to an existing sauce kitchen — all coordinated with a prime contractor and multiple OEMs, all delivered with a Category 3 safety system on top.
The challenge
Multiple aggressive milestones tied to a single product launch. Multiple OEMs, all with their own schedules. And a non-negotiable safety standard built into every line.
What we did
- Stood up communication channels with the client, prime contractor, OEMs, and other contractors so information moved as fast as the schedule.
- Applied disciplined project management — scope, budget, schedule, quality — against the prime contractor’s master plan.
- Wrote modular PLC code so common functions only had to be built once.
- Implemented the required Category 3 safety system on Allen-Bradley GuardLogix.
The outcome
- Hit the aggressive startup schedule and the launch date that depended on it.
- Delivered on time and under budget.
- Provided ongoing remote support during the project-to-production transition so operators were never alone.
Key Results
On Time
New Product Launch
Under
Project Budget
24/7
Remote Support After Startup
Technology Stack
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