Case Studies

The Coconut Cult scaled from 13,000 to 300,000 square feet in five years. IPM engineered and integrated a fully automated line from the filler through palletizing — anchored by a three-robot KUKA cell — that gave the brand roughly 10× the throughput while preserving its artisanal production standards.

A leading beverage manufacturer needed to increase variety pack production to meet growing demand from big box retailers. Its existing manual packaging process had become increasingly difficult to sustain at higher production volumes. IPM engineered and integrated a new automated variety pack packaging line to replace the manual process, ultimately scaling to three facilities.

A global dairy producer needed to expand string cheese packaging capacity to support growing demand while maintaining the flexibility required to accommodate a large and complex SKU mix. The project involved two new fully automated secondary packaging lines serving major retail channels.

The high-speed packaging lines needed to support production rates of up to 1,440 string cheese sticks per minute while accommodating multiple package counts, case formats, and pallet configurations.

The operation required a secondary packaging system capable of supporting frequent product changeovers, maintaining production efficiency, and adapting to evolving facility requirements while preserving throughput and future growth potential.

Project Overview A dairy producer needed IPM to engineer gabletop packaging solutions for two related applications: a single-quart line project

Project Overview

A major cheese producer needed to merge two new block cutting production lines into a single trunk line while preserving the shape, stability, and quality of 40 lb cheese blocks. The operation required precise case handling, continuous product flow, and a palletizing process that met strict labeling and documentation standards, all within a highly constrained footprint.