Case Study: Consumer Goods Packaging Company achieves automated continuous batch mixing, 25% mixing labor reduction and real-time regulatory data with Hertzler Systems Inc

Blending the right reasons with GainSeeker Suite to make a sensible investment

The Consumer Goods Packaging Company faced rising pressure to increase throughput and line uptime by automating a formerly manual ingredient-mixing process that fed four fill lines across two plants. They needed to eliminate time-consuming changeovers and manual mixing (which consumed about 25% of the mixing department’s workload), while also retaining regulatory-quality documentation and longer-term process data—requirements that their PLCs alone could not meet. To address this, they turned to Hertzler Systems Inc and its GainSeeker Suite.

Hertzler Systems Inc deployed GainSeeker Suite to collect PLC data from flow meters, calculate and store per-cycle weights and ingredient percentages, and trigger real-time alarms that notify engineers when trends appear. The solution created a historian and automated alerts that improved process visibility, supported preventive maintenance, and provided audit-ready documentation. As a result, the company eliminated much of the manual mixing work (about 25% of the department), fed multiple lines more reliably, captured the data needed for regulators, and achieved a payback in roughly eight months while building on prior quality gains (99% First Pass Yield).