KWS Minimizes Downtime at Corrugated Container Manufacturing Facility in North Carolina

Introduction

Fiber-based materials are used to package millions of consumer and industrial products each year. The market is expected to grow from $400 billion in 2023 to over $600 billion in 10 years. The positive growth rate includes an increasing focus towards sustainability. Screw conveyors are used in the making of corrugated and other fiber-based packaging materials.

Challenge

A corrugated container manufacturing facility in North Carolina experienced a catastrophic failure of a screw conveyor and needed a replacement screw ASAP. KWS was immediately contacted with replacement screw specifications. The screw was very special and made-to-order with 36-inch diameter flights, AR400 material, and 3-15/16-inch diameter shafts. Typical lead times are two weeks or longer.

KWS Advantage

A plan was developed between the KWS sales and manufacturing teams to make sure downtime was minimized for our customer. KWS immediately went to work and expedited the manufacturing process from 15 to 2 days. Working 24 hours per day, KWS completed and shipped the screw within 48 hours of receiving the distress call from our customer. The finished screw was then shipped by dedicated truck and arrived in North Carolina the next day.

KWS eliminated over 300 hours of downtime, exceeding customer expectations and saving valuable time and money. The customer realized over $3,000,000.00 in potential downtime savings.