From 11 Conveyors to 5 — Without Losing a Single Kilogram
How a leading nuts & dried fruit manufacturer in Vietnam cut capital costs by $100,000 through flow optimization.
Too Many Conveyors. Too Much Cost.
A leading nuts and dried fruit manufacturer in Vietnam was planning a new production line and had initially designed a layout requiring 11 conveyors to move product from processing through to packaging. The complexity of the layout meant higher capital expenditure, more maintenance touchpoints, and a greater risk of spillage and breakage at each transfer point.
The challenge wasn't just cost — it was designing a conveyor system that could handle delicate nuts and dried fruits at the required throughput without compromising product integrity or hygiene standards.
High CAPEX and maintenance load
Spillage & breakage risk at every transfer
$100,000 lower capital cost
Gentle, hygienic handling preserved
Fewer Conveyors. Smarter Flow.
Enabling.Win conducted a full plant survey and flow analysis, applying its Understand → Reduce → Identify → Solve methodology. By re-evaluating the role of every conveyor in the line, the team identified redundant transfer points and re-engineered the layout to achieve the same throughput with fewer machines.
- Full plant survey and flow analysis (Understand → Reduce → Identify → Solve)
- Redundant transfer points identified and removed
- Layout re-engineered from 11 conveyors to 5 — a 55% reduction with no loss of capacity
- Each conveyor custom-engineered with optimized belt width and synchronized side walls for spillage prevention
- Precision-designed transfer points to handle the fragile product gently
The result came from treating conveyors not as commodity equipment, but as engineered flow assets. By analyzing what each conveyor was actually doing in the line — and which ones added complexity without adding value — Enabling.Win designed a leaner, more reliable system that cost significantly less to build and maintain. This project demonstrates the direct ROI of flow optimization before capital is committed — the highest-leverage point in any plant design.
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