“The model guided us from initial concept through to commissioning—we knew exactly what capacity we’d get before the equipment arrived.”
— Engineering Director
The Challenge
A healthcare manufacturer had identified a market opportunity for a new range of high-margin mouthwash products, but their existing blending, bottling, and packing operation was already running at capacity. To launch the new range, they needed to invest in additional capacity—but couldn’t justify £7 million in capital expenditure without confidence that the investment would deliver the required output.
The existing operation had constraints that weren’t fully understood. Was the bottleneck in blending, bottling, or packing? Would a new line integrate smoothly with existing infrastructure? What capacity would they actually achieve once the new equipment was commissioned? These questions needed answers before the investment could proceed.
The Solution
We built a model of the complete mouthwash operation—blending, bottling, and packing—that served as the foundation for the entire project, from initial feasibility through equipment selection, detailed design, and commissioning of the new line.
Constraint Identification
The model mapped the existing operation to identify exactly where capacity was being limited. By tracing product flow from raw materials through blending vessels, filling lines, and packing stations, we pinpointed the constraints that were preventing growth—and quantified how much additional capacity each intervention would unlock.
Investment Validation
Before committing to the £7 million investment, we modelled the proposed new line alongside existing operations. This confirmed that the investment would deliver the required capacity increase and that the new line would integrate with existing blending and utilities infrastructure without creating new bottlenecks elsewhere in the system.
Project Development Support
The model wasn’t a one-time deliverable—it evolved with the project. As equipment specifications were finalised and layout decisions were made, the model was updated to reflect the emerging design. This allowed the team to test decisions against capacity targets throughout the project lifecycle, catching potential issues before they became expensive problems.
Commissioning Confidence
By the time the new line was installed, the team already knew what performance to expect. The model provided commissioning targets based on realistic operational parameters, not supplier claims. This meant faster ramp-up and earlier realisation of the capacity needed to launch the new product range.
The Results
The model de-risked a major capital investment and enabled commercial growth:
30% increase in production capacity by identifying and addressing the true constraints in the blending, bottling, and packing operation.
£7 million investment validated with modelled performance data, giving the board confidence to approve the project.
New product range launched with the capacity needed to meet market demand for high-margin mouthwash products.
Concept-to-commissioning support with a model that evolved alongside the project, testing decisions at every stage.
Faster ramp-up with realistic commissioning targets based on modelled performance rather than equipment specifications.
The manufacturer turned a capacity constraint into a growth opportunity—with a model that proved the business case and guided the project from first proposal to production.