MetaExperts Logo

MetaExpert Packs a Big Punch with Protein Bar Packaging Overhaul


A manufacturer of protein bar packaging recently relocated from a 50,000-square-foot operation facility to a new 350,000-square-foot operation facility. This resulted in an assembly line production change where stand-up assembly packaging lines were converted to brand-new automated packaging lines. In addition, there was a folding carton redesign where the Straight Tuck End folding cartons were replaced by new Top Kliklok folding cartons. The manufacturer also transitioned to and needed to integrate a new international packaging equipment supplier. Finally, the company needed a new documentation system for more accurate data collection and organization from start to finish.

The manufacturing company hired the MetaExpert, a packaging engineering expert with ample experience to design, measure, analyze, improve, and control the entire packaging process from location A to location B.


Over the course of an 18-month contract, the MetaExpert took the following actions and strategies to evaluate and retool the packaging manufacturer’s processes:

  • Voice of the Customer
  • Data Collection
  • Product + PKG Collection
  • Scope
  • Manage a PKG Timeline
  • Designs (via CAD)
  • Designs (via Samples)
  • Develop a Test Plan
  • Testing & Reporting
  • Calculate Cost Savings
  • Develop New Specs


Thanks to the MetaExpert's acumen in packaging engineering and process improvement, the manufacturing company saw immediate and measurable results.

  • Organized 50 new top-load bar orientations for the new top-load cartons
  • Set up and designed over 100 new packaging material specifications
  • Managed and organized 50 new tray formers
  • Managed and organized 50 new case-packing grippers
  • Re-designed all packaging pallet patterns in TOPS for the new automated palletizers
  • Managed and organized all international package testing and reporting
  • Created one centralized organized, interim spreadsheet for all packaging information and pre-documentation system implementation

Return on Investment

A skillful evaluation and overhaul of the packaging process by the MetaExpert yielded a massive increase in packaging speed from 30 bars/minute to 300 bars/minute. That’s a 900% increase in just 18 months!


See what MetaExperts can do for you

Find a MetaExpert

Ready To Get Started?
Schedule a Call Now

Get MetaExperts™ & Get it Done Now

With one phone call, email, or clicking a link schedule a time to speak with the MetaExperts™ sourcing expert. You are just minutes away from getting your improvement initiative started or re-energized.

Contact NowBecome a MetaExpert

©2021 All rights reserved, MetaOps, Inc.


Corporate Address:
10343 RS Avenue
Mattawan, MI 49071
Canadian Address:
168 Beaconsfield Blvd, Beaconsfield, 
QC H9W 4A1
Mexico Address:
Circunvalación Sur 115A, Int. 6, Las Fuentes
Zapopan, Jalisco, Mexico, 45070


[email protected]
envelopephone-handsetchevron-down linkedin facebook pinterest youtube rss twitter instagram facebook-blank rss-blank linkedin-blank pinterest youtube twitter instagram