We started in beer and spirits, spent two decades expanding through beverage and ingredient markets, and today serve nearly every niche and staple food segment you can think of. Disruptive Process Solutions’ experience is rooted in solving complex process challenges, both on the production floor and in the operations suite alike.
Prepared Food & Ingredients
Snack, confection, sauce, slurry, flavor/color, supplement, cannabis, and powder processing are all found in our history of successful projects. For both bulk re-pack and consumer products, we understand the vast range of nuance that lives within prepared food recipes, and can help translate those requirements into operational principles on the plant floor. Specific expertise in this arena includes SKU change-over optimization for co-packers, hygienic and allergenic requirements for plant design, and data-driven continuous improvement solutions.
Consumer Packaged Goods
Consumer Packaged Goods manufacturers have faced incredible challenges, especially since the pandemic. With tightening regulations, increasing labor costs, and output constraints, every CPG manufacturer is facing several obstacles. Our clients look to DPS to help transform their complex operations into a world-class automated businesses. For most CPG clients, we like focusing on understanding their current operations first and then determining the least cost method to increase their capacity while limiting labor spend.
Beverage
Aseptic and Pharma
Aseptic and pharmaceutical design is critical in providing shelf-stable and medical grade products that keep both product and consumer safe. Not only the process has to be designed correctly but its standard practice to ensure the facility and ancillary equipment surrounding the solution can keep up without sacrificing quality. DPS’s expertise and experience will allow our clients to focus on what matters. We will evaluate your product, co-develop a solution, and execute the entire project from ground up.
Capital Planning and Feasibility
Capital Planning, Scheduling, and Project/Program Feasibilities are the core of DPS’s beginnings. We strongly believe that Capital Planning is the of the most under-utilized tool for our clients. DPS built its business foundations on capital planning for multiple food and beverage manufacturers, specifically aligning business growth goals with technical requirements, project scoping, and project budgeting. We minimize client budget risks by planning jobs appropriately with proper scoping – including operational downtime and permitting timelines.
Operations Optimization
Operational modeling is critical for understanding the full capacity of line capacities and SKU management. One of our standard offerings is evaluating real line capacity per product. Every product has its own line capacity and in order to accurately depict the true line capacity, we do an in-depth review of each step in the manufacturing process. We find the most effective tool is comparing actual production output against a calculated output. Our calculated output identifies weaknesses in the production line and we propose optimizations to maximize the output. We find optimizing (and finding new capacity) is normally the best return on your investment – whether through increased sales, maintenance downtime availability, or the elimination of a shift or weekend work.