They were preparing to expand. CareGo made the expansion unnecessary.
Growing local demand was pushing this toll processor to the limits of its available real estate. CareGo redesigned how product was stored, organized, received and shipped, creating enough capacity to keep the operation under one roof and invest elsewhere instead.
Capital / Space
Expansion avoided
Capacity
3 bays became 2
Business
Operation kept in house
Flow
Shipping & receiving simplified
1The constraint
Growth was forcing a capital decision.
Rising demand was outpacing the facility's capacity. Leadership faced a strategic choice with real consequences for capital, risk and the long term flexibility of the business.
The real question was not whether they needed more space. It was whether the current environment could do more.
- A
Expand facility
- High capital investment
- Longer timeline
- Construction risk
- B
Outsource part of the operation
- Less control
- Additional cost
- Service risk
- C
Change what the current facility can do
- Use existing footprint
- Increase capacity
- Grow in house
The
path
2Capacity
Three bays became two.
CareGo condensed the entire operation enough to reduce three required bays to two, unlocking space and improving throughput without adding a square foot.
Key solution element: alternating 2 high and 3 high coil storage.
Before: 3 bays
2 high coil stacking
1
2
3
3 × 8 = 24 coils. Three bays required to meet demand.
With: 2 bays
3 high coil stacking
1
2
2 × 12 = 24 coils. Same capacity in two bays.
3Business impact
More capacity changed the economics.
Expansion no longer required
Avoided millions in capital investment and project risk.
Growth stayed in house
Maintained control, quality and customer service.
Capital could be invested elsewhere
Freed capital for strategic growth and other priorities.
Existing footprint became more productive
More throughput, better efficiency, lower cost per ton.
Risk reduced before go live
Flow, capacity and crane coverage were validated in simulation before construction.
Crews prepared from day one
Operators trained in the digital environment before the facility opened.
4Flow / shipping & receiving
More density only works if material can still move.
This project introduced TELIA features Fly Ship and Fly Receipt to simplify shipping and receiving and keep material flowing.
Typical workflow
- Receiving
- Store
- Retrieve
- Stage
- Ship
With+
- Fly ReceiptDirect to strategy
- StoreOptimized placement
- RetrieveIntelligent sequencing
- StageStreaming to door
- Fly ShipLoad & go
5Brownfield transformation
CareGo worked with the facility that was already there.
We did not start over. We built on what the facility already did well, integrating systems and strategies to unlock more value from existing assets.
Existing facility
Existing specialized bunking
Better storage strategy
TELIA
Shipping / receiving logic
Expansion avoided
6How CareGo did it
TELIA
Intelligence that drives better decisions in real time.
Specialized bunking integration
We retained and integrated the customer's specialized bunking.
Alternating 2 high / 3 high storage
Higher density without compromising access or safety.
Fly Ship
Load smarter, skip unnecessary staging, ship faster.
Fly Receipt
Receive, validate and store with minimal handling.
7What this means for your role
Owner
Better asset utilization and long term enterprise value.
CEO
Sustainable growth without adding real estate.
CFO
Avoided expansion can free capital for other priorities.
VP of Operations
More throughput, fewer bottlenecks, smoother flow.
Plant Manager
Simplified operations and better day to day execution.
Want a result like this in your facility?
Tell us about your operation and what it needs to achieve.