Conversion Line Upgrade

Salas O’Brien executed a first-of-its-kind project for a major family goods manufacturer. We upgraded the client’s paper product conversion line from an outdated controls system by implementing the latest technology and utilizing the Lean Integrated Project Delivery (IPD) approach. This strategy involved collaboration between all project partners from day one for a more efficient execution with less waste, risk, and downtime. We updated the drives to Allen-Bradley Kinetix 5700 and all of the Input/Output (IO) and pneumatics to Ethernet IO. The client trusted us to engineer the first controls upgrade of its kind for this production line, with plans to implement our design across all related lines. To prepare for construction, we designed the equipment layouts, created 3D models, generated installation instructions, and outlined utility connections. Additionally, we provided construction support, startup, and sustaining services to deliver a state-of-the-art conversion line. The project’s success prompted the client to engage us for an additional new line as part of their capacity expansion.