--- title: Packaging Expansion Unintentionally Prepared Manufacturer for the Pandemic description: Discover how a Fortune 100 CPG company successfully reconfigured their palletizer area to meet the increasing demand for larger bundled products. image: https://info.polytron.com/hubfs/Blog/Feature%20Images/Packaging%20Expansion%20Unintentionally%20Prepared%20Manufacturer%20for%20the%20Pandemic.webp --- [Polytron Named Top Work Place   Learn More](https://info.polytron.com/blog/polytron-receives-back-to-back-top-workplace-honors) [![Polytron Tagline Logo 350](https://polytron.com/wp-content/uploads/2024/10/Polytron-Tagline-Logo.png)](https://polytron.com) - [Services](https://polytron.com/services/) Close Services Open Services - [Industries](https://polytron.com/industries/) Close Industries Open Industries - [Resources](https://polytron.com/resources/) Close Resources Open Resources - [About Us](https://polytron.com/about-us/) Close About Us Open About Us [Packaging](https://polytron.com/services/packaging/) [Process Control](https://polytron.com/services/process-control/) [Industrial Network and Security](https://polytron.com/services/industrial-network-and-security/) [Automation and Controls](https://polytron.com/services/automation-and-controls/) [Machine Safety](https://polytron.com/services/machine-safety/) [Capital Projects](https://polytron.com/services/capital-projects/) [Predictive Maintenance](https://polytron.com/services/predictive-maintenance/) [Obsolescence Upgrades](https://polytron.com/services/obsolescence-upgrades-and-modernization/) [Mechanical Engineering](https://polytron.com/services/mechanical-engineering-services/) [Front-End Engineering](https://polytron.com/services/front-end-engineering-services/) [Simulation and Emulation](https://polytron.com/services/simulation-and-emulation/) [Smart Manufacturing](https://polytron.com/services/smart-manufacturing/) [![Mega-Menu_Food-Beverage-v2-300x200](https://info.polytron.com/hs-fs/hubfs/Mega-Menu_Food-Beverage-v2-300x200.webp?width=300&height=200&name=Mega-Menu_Food-Beverage-v2-300x200.webp)](https://polytron.com/industries/food-and-beverage/) ## [Food & Beverage](https://polytron.com/industries/food-and-beverage/) [![Mega-Menu_Consumer-Packaged-Goods-v2-300x200](https://info.polytron.com/hs-fs/hubfs/Mega-Menu_Consumer-Packaged-Goods-v2-300x200.webp?width=300&height=200&name=Mega-Menu_Consumer-Packaged-Goods-v2-300x200.webp)](https://polytron.com/industries/consumer-packaged-goods/) ## [Consumer Packaged Goods](https://polytron.com/industries/consumer-packaged-goods/) [![Mega-Menu_Chemicals-v2-300x200](https://info.polytron.com/hs-fs/hubfs/Mega-Menu_Chemicals-v2-300x200.webp?width=300&height=200&name=Mega-Menu_Chemicals-v2-300x200.webp)](https://polytron.com/industries/chemicals/) ## [Chemicals](https://polytron.com/industries/chemicals/) [![Mega-Menu_Life-Sciences-v2-300x200](https://info.polytron.com/hs-fs/hubfs/Mega-Menu_Life-Sciences-v2-300x200.webp?width=300&height=200&name=Mega-Menu_Life-Sciences-v2-300x200.webp)](https://polytron.com/industries/life-sciences/) ## [Life Sciences](https://polytron.com/industries/life-sciences/) [All Resources](https://polytron.com/resources/) - Brochures - Guides  - Videos - White Papers [![](https://polytron.com/wp-content/uploads/2026/03/Mega-Menu_Case-Studies-300x200.webp)](https://info.polytron.com/case-studies) [![](https://polytron.com/wp-content/uploads/2026/03/Mega-Menu_Blog-300x200.webp)](https://info.polytron.com/blog) [![Mega-Menu_About-v2-300x200](https://info.polytron.com/hs-fs/hubfs/Mega-Menu_About-v2-300x200.webp?width=300&height=200&name=Mega-Menu_About-v2-300x200.webp)](https://polytron.com/about-us/) ## [About Us](https://polytron.com/about-us/) [![Mega-Menu_Leadership-v2-300x200](https://info.polytron.com/hs-fs/hubfs/Mega-Menu_Leadership-v2-300x200.webp?width=300&height=200&name=Mega-Menu_Leadership-v2-300x200.webp)](https://polytron.com/leadership/) ## [Leadership](https://polytron.com/leadership/) [![Mega-Menu_Careers-v2-300x200](https://info.polytron.com/hs-fs/hubfs/Mega-Menu_Careers-v2-300x200.webp?width=300&height=200&name=Mega-Menu_Careers-v2-300x200.webp)](https://polytron.com/careers/) ## [Careers](https://polytron.com/careers/) [Contact us](https://polytron.com/contact-us/) [Packaging](https://info.polytron.com/blog/tag/packaging) # Packaging Expansion Unintentionally Prepared Manufacturer for the Pandemic By [Polytron](https://info.polytron.com/blog/author/polytron) May 6, 2021 1 Minute Read A Fortune 100 CPG company needed to provide larger bundled product to meet demand from customers searching for volume discounts offered at club warehouses. The manufacturer’s palletizer area was designed to handle cases— not consumer-ready product bundles.Without severely disrupting the plant’s current production, the company needed to reconfigure the palletizer areas and redesign the conveyor lanes to move the newly configured product effectively and efficiently from production to shipping. ## **Increased Flexibility and Efficiency** Once the line was redesigned, the manufacturer had more control over how bundled products moved through the line, onto forklifts, and out of the plant. Now, product can be bundled onto pallets in stacks of any number, shrink wrapped, and shipped. As a result, the plant has the flexibility to expand capacity to meet the new demand from consumers without disrupting existing lines or investing more capital. The plant can meet demand as the market changes and increase volume based upon projected sales. The plant knows what it can deliver today and the peak capacity it is able to deliver – which allows sales and marketing to communicate clearly and accurately with both retailers and other customers. ## **Unintentional Preparation for the Future** Expanding packaging capacity for the manufacturer was complete before the COVID-19 pandemic. Due to flexibility and throughput, the manufacturer was better positioned to take on consumer demand from panic buying during the pandemic. The plant is more productive with the downstream material handling and palletizing systems able to “take away” all new product sizes with the increased line speed. In addition, this manufacturer can provide even more varieties of product to its key retail customers. Want to learn more about the design plan and installation of the new line? [Read our case study.](https://polytron.com/resourcesinsights/expanding-packaging-capacity/) [![Picture of Polytron](https://info.polytron.com/hubfs/LI%20Newsletter%20Icon.png)](https://info.polytron.com/blog/author/polytron) #### Polytron For 40 years, Polytron has delivered thousands of manufacturing solutions to help its clients improve productivity, meet their business challenges, and drive profitability. Polytron delivers manufacturing solutions based on our expertise in process and packaging, automation, networking, machine safety and cybersecurity systems and solutions. Our team of certified and experienced engineers work with our customers to help solve their most difficult manufacturing challenges. Manufacturers are experts at what they make. We are experts at providing innovative and sustainable technology solutions that solve the manufacturer’s problems. 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