OVERVIEW
A global beverage manufacturer undertook a $50M investment in a new high-speed packaging line, alongside ongoing operations across multiple existing packaging lines and brewhouse processing systems.
To ensure successful commissioning and sustained performance, they required embedded automation and controls expertise.
THE CHALLENGE
The client needed to:
- Commission a new high-speed packaging line within aggressive timelines
- Maintain uptime across existing packaging and brewhouse systems
- Resolve complex multi-OEM automation challenges
- Minimize startup risk, downtime, and inefficiencies
- Enable long-term continuous improvement and system reliability
THE SOLUTION
DASH Engineering deployed embedded Automation & Controls Engineers to support commissioning and plant operations.
Commissioning & Startup
- Led I/O checkout, system validation, and functional testing
- Provided real-time troubleshooting during startup
- Coordinated with OEMs and plant teams to optimize performance
Plant-Wide Controls Support
- Supported existing packaging lines and brewhouse systems
- Monitored system performance and SCADA data to identify improvements
- Executed preventive and corrective maintenance to minimize downtime
Controls Engineering
- Performed PLC/HMI updates, parameter tuning, and system optimization
- Conducted advanced diagnostics and root cause analysis
- Replaced and reconfigured critical automation components
Collaboration & Continuous Improvement
- Partnered with plant teams to drive continuous improvement initiatives
- Delivered training and knowledge transfer to maintenance staff
- Produced monthly performance reports to guide decision-making
THE IMPACT
DASH Engineering enabled a fast, low-risk commissioning of a major capital investment while improving performance across existing operations. The engagement delivered measurable gains in OEE, uptime, and throughput, creating a strong foundation for long-term operational excellence.
