When a leading detergent producer in Brazil came to us, they had a clear objective: double production output without expanding factory space. Their existing lines were already running at capacity, and building a new facility was not an option due to cost and time constraints.
Discovering the Bottleneck
During our assessment, we found that the company relied on pre-manufactured PET bottles, which not only consumed warehouse space but also limited flexibility. Their filling machines were functional but not optimized for high-speed integration with packaging systems. The real challenge was to free up space while increasing line efficiency.
Our Solution
We designed an integrated line combining an ASFL blow molding machine, a high-speed filling machine, and a flowpack system for secondary packaging. By producing PET bottles on-site, the customer eliminated the need for large storage areas. The high-speed filler ensured accurate dosing, while the flowpack system stabilized products for long-distance transportation across South America.
The Results
Within the first quarter after installation, the customer achieved 100% growth in output without expanding floor space. Logistics losses from weak seals and unstable packaging dropped by 25%, and operators praised the user-friendly controls and seamless integration.
“We never thought it was possible to double production without building a new plant. ASFL’s integrated blow molding and filling solution made it happen,”
— Roberto Silva, Plant Manager, RioClean Detergents
Why It Matters
This project proved that space efficiency and production growth can go hand in hand. By integrating blow molding, filling, and flowpack packaging, ASFL helped RioClean Detergents not only double their capacity but also strengthen their distribution reliability across South America.
