A leading paper products manufacturer operating three plants in the Southeastern United States was facing significant and recurring production downtime in its paper plate operations. The plants frequently experienced bottlenecks and system backups when stacks of plates fell over or clogged the conveyor systems. These events often resulted in hours of lost production as operators shut down lines to clean and reset equipment.

Compounding the issue, bottlenecks shifted depending on the product configuration and stack height, forcing operators to slow down packaging or downstream systems to maintain flow. Inconsistent product handling, limited personnel availability during changeovers, and a lack of visibility into system dynamics further complicated the problem.

At the same time, the company was considering several debottlenecking and capacity expansion projects at its largest facility. Before investing in capital improvements, the client needed a clear, data-driven understanding of where and why bottlenecks occurred and how to optimize operations across the network.

Caravel Solutions leveraged its advanced process modeling and simulation expertise to develop a digital twin of the first plant as a pilot. The simulation was so effective that it was subsequently expanded to include all three facilities.

The comprehensive models included:

• Plate presses, conveyors, packaging, sorting, and robotic handling systems

• Startup and shutdown sequences, including paper roll changeovers and packaging line adjustments

• Material and personnel movement dynamics to identify inefficiencies and downtime drivers

By simulating real operating conditions and product mix variations, Caravel provided the client with a powerful visualization of plant interactions, revealing how certain products and configurations created systemic bottlenecks. The model became a tool not only for problem diagnosis but also for scenario testing and decision-making around future CAPEX investments and production planning.

The simulation enabled Caravel and the client to implement production planning rules that defined “compatible product groupings,” ensuring smooth flow across systems and minimizing bottlenecks caused by mismatched product configurations.

Key outcomes included:

• Reduced changeovers and downtime through optimized production sequencing

• Improved reliability via targeted technology and process adjustments

• Enhanced decision-making for CAPEX projects, using the simulation to test multiple expansion and debottlenecking scenarios across all sites

The initiative delivered an EBITDA impact exceeding $12 million per year, driven by higher uptime, improved throughput, and smarter capital deployment.

Caravel Solutions’ data-driven, systems-based approach empowered the client to move from reactive problem-solving to proactive optimization, transforming operational complexity into a competitive advantage.