Reducing Costs & Enhancing Efficiency in Beverage Packaging

Value Optimization/PIR Packaging System Redesign & Cost Savings

Client Needs

A popular beverage company required a redesign of Packaging System of at home and away from home brewers to be more sustainable and cost reduction

The Challenge

Complicated global supply chain, client had above industry average test requirements, finished good costing without clear breakout of packaging costs, secondary fulfillment done in the United States.

Our Approach

  •  Analysis of client supply chain from manufacturing through 3pl, retailers, and end consumers 

  • Custom mapping of using real time trackers of the actual supply chain to develop custom testing profile 

  • Fragility testing of product to determine g levels 

  • Optimization of design to increase truck/container density 

  • Change from EPS foam cushions to molded fiber 

  • Cost modeling to determine in country costing 

  • Color Management across global supply chain, testing and validation with support through commercialization.

The Impact

  • $18mm in annual material and logistics savings 

  • Increased the sustainability of packaging 

  • Increased truck density 13% 

  • Decreased 3PL labor costs on fulfillment of pods 

  • Controlled color globally within delta 2

Value to Client

Adept helped a leading beverage company redesign its packaging system for both at-home and away-from-home brewers, achieving $18 million in annual material and logistics savings while enhancing sustainability. 

By mapping the supply chain with real-time trackers, conducting fragility testing, and optimizing truck density by 13%, Adept significantly improved efficiency and cost control. 

The transition from EPS foam to molded fiber further supported sustainability goals, while color management standardization ensured global brand consistency. These efforts also streamlined fulfillment operations, reducing 3PL labor costs and strengthening the company’s packaging performance and supply chain resilience.

Let’s Talk Efficiency Gains

Want to reduce production costs, increase throughput, or optimize your packaging line? Let’s connect.

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