CLIENT PROFILE Industry: FMCG — packaged snacks and namkeen
Location: Industrial Area, Ghaziabad, Uttar Pradesh
Application: Integration of 6 packing machines to central carton accumulation and dispatch conveyor
Challenge: Six packing machines were operating as isolated units. Finished product cartons were moved manually by 5 workers between machines, a central weighcheck station, and the dispatch area — creating bottlenecks, physical fatigue, and a throughput ceiling that couldn't scale with growing demand.
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THE CHALLENGE
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The plant was running at 68% of its theoretical maximum throughput. Every bottleneck traced back to manual carton movement. The client had a seasonal peak season 4 months away and needed the upgrade commissioned before it.
Budget constraint: The client had been quoted ₹28 lakhs by another supplier for a fully automated system. Their budget was ₹14–16 lakhs. They came to Neo Conveyors asking if anything meaningful was possible within budget.
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NEO CONVEYORS SOLUTION
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Our engineering team visited the plant, mapped the existing layout, and designed a phased conveyor integration that worked within budget while solving the core bottleneck:
Phase 1 — Machine-to-main-line connections (commissioned first):
• 6 × short take-away belt conveyors (1.5m each, 400mm wide) — one from each packing machine discharge
• All 6 feeds into a central 18m × 500mm flat belt main conveyor (MS frame, PVC belt)
• 1 × 90° roller transfer corner unit routing to weighcheck station
• Speed-synchronised with packing machine outputs via VFD
Phase 2 — Dispatch integration (commissioned 10 days after Phase 1):
• 12m inclined belt conveyor rising 1.2m to palletising mezzanine level
• 8m powered roller accumulation conveyor at mezzanine for pre-palletising buffer
• PLC panel controlling entire system with individual machine on/off isolation
Total system: 14 conveyor units, 58m total conveying length
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DELIVERY & INSTALLATION
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• Design and layout approval: 3 days
• Phase 1 fabrication and installation: 9 working days
• Phase 2 fabrication and installation: 10 additional working days
• Full system PLC commissioning and operator training: Day 19
• Total project cost: ₹15.4 lakhs (within agreed budget)
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RESULTS — 18 MONTHS AFTER COMMISSIONING
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✅ Manual carton handling workforce reduced from 5 workers to 1 supervisor
✅ Throughput increased from 68% to 99% of theoretical maximum — a 45% improvement
✅ First peak season after installation: zero bottleneck incidents, record monthly output
✅ Zero unplanned downtime in 18 months of double-shift operation
✅ ROI achieved in 11 months (labour saving alone: ₹1.2 lakhs/month)
✅ Client has referred 3 other FMCG manufacturers to Neo Conveyors
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CLIENT FEEDBACK
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'We were told ₹14 lakhs was not enough for what we needed. Neo Conveyors designed a phased solution that solved our exact problem within budget. The system ran through our busiest peak season without a single issue. We have since referred three other manufacturers to them.'
— Factory Manager, FMCG Plant, Ghaziabad
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Budget constraint? Tell us your number — we will engineer around it.
🌐 https://www.neoconveyors.com/products/inspection-conveyors
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