Case studiesDairy · In-plant
An in-plant partnership that took transport miles to zero.
We relocated bottle production inside the customer’s filling site, collapsing lead times to hours and putting two engineering teams in the same room.
- SectorDairy
- ServiceIn-plant model
- MaterialHDPE / rHDPE
- Transport milesZero
The challenge
A high-volume dairy customer was moving bottles long distances between a remote moulding site and their filling hall, adding cost, carbon and lead time at every step. Every bottle was being handled, loaded, transported and unloaded before it ever reached the filler.
What we did
- 1Scoped an implant arrangement inside the customer’s filling site.
- 2Installed blow-moulding cells, services and tooling alongside the line.
- 3Embedded our operators and engineers shift-for-shift with the customer’s team.
- 4Set up a shared planning rhythm so production and filling stay in step.
“Having First Circle on site changed how we work. Decisions that used to take days now happen on the floor in minutes.”
The result
Lead times dropped from days to hours, transport miles between moulding and filling fell to zero, and both teams now problem-solve in person, every day. The partnership has run and grown for years rather than renewing as a contract.
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