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Case Stories

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Sunny Delight

Intellectualizing that nearly 60 different manufacturing facilities all across the US should each function as efficiently and effectively as the other is one thing, but having them all function that way - in day to day practical application, is quite another. That is, until CCC implemented our Consolidated Production System (CPS) to drive and manage consistent manufacturing practices.

One such example of how CPS proved its worth is at our Fulton plant – one of three local Atlanta area manufacturing facilities. CCC Fulton makes plastic bottles for the Sunny Delight Beverage Company.

CCC’s Consolidated Production System is designed to drive out waste, improve quality and reliability, and create more value for the company and its customers. Our dedicated operators and technicians have committed to driving these results through extra metrics charting, progress tracking and overall analysis. In addition to the procedural changes, CPS encourages machine upgrades, equipment changes and more extensive preventive maintenance. Better maintenance means less time in contact with the machines, which saves time and improves operator and maintenance safety.

Dramatic improvements are being seen in first pass yield, speed loss, uptime loss, and overall equipment effectiveness. With the new CPS processes, bottle losses are corrected as they occur in order to avoid larger losses caused by delays. As a result, our facilities are eliminating losses throughout the entire facility—not just in downtime or bottle loss.

Customer satisfaction is another outcome of CPS; CCC won a multi-year contract with Sunny Delight, because we became a much better supplier for them - through our CPS program!

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High Pressure Pasteurization

Innovative food and beverage processing techniques call for innovative plastic packaging.

Such is the case here. CCC detected a growing market demand for High Pressure Pasteurization (HPP) - where food or beverage is subjected to extremely high pressures to destroy pathogenic microorganisms. In response to this emerging market, we proactively researched HPP technology and related packaging requirements, and developed relationships with HPP processing equipment manufacturers. We continued our research into closure systems and began to build relationships with those suppliers as well.

Progress continued as CCC created state-of-the-art design features for our HPP packages that would stand up to the rigors of HPP processing while also meeting the brand and commercial needs of our customers. We then worked with our PET preform suppliers and engineering team to determine the best combination of closures, raw materials, and molding processes – specifically to support HPP processing.

From all of this innovative work, we created various HPP plastic bottle designs that met the size, shape, and branding requirements emerging product companies are looking for. Today, we are proud to say that CCC has rigid packaging solutions for the HPP marketplace that are currently being introduced to new and current customers.

Our Engineering Development Center, in partnership with our design entity, Studio PKG, is continually developing and testing exciting new innovative materials, designs, and technologies that will support our customer’s needs, including supply chain optimization and regulatory compliance. Through these efforts, we seek to continually improve - and advance our innovations - to ensure our packaging solutions are ‘Always Made Right.’

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Seventh Generation

When household product company “Seventh Generation” named their brand, they made a promise to consider the effects their present actions would have on the well-being of the next seven generations—roughly 140 years into the future. This ecological concept, based upon Native American beliefs, drives the company to continually promote sustainable lifestyles and always work in a way that will benefit future generations.

As one of Seventh Generation’s key plastic bottle manufacturers, we at Consolidated Container Company wholeheartedly agree with this notion. In fact, we’ve designed nearly a dozen of their product packages to date—producing over 23,000,000 bottles for them in 2014 alone. These aren’t just any plastic bottles. Most of the plastic packaging we blow mold for Seventh Generation contain 100% PCR (post-consumer regrind) content, not including colorant. Not only are these packaging solutions environmentally friendly, but also chlorine-free and phosphate-free.

CCC’s practice of using recycled plastic to make new bottles reduces our carbon footprint, and drives best practices in PCR use for sustainability. We are proud to partner with Seventh Generation as they continue to produce responsible cleaning and personal care products for today’s consumers that will support many generations to come.

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Talenti

For any of you who’ve tasted Talenti Gelato, our guess is that you’ll agree with their slogan, “Better ingredients make happy spoons.” CCC helps make spoons happy, by making the plastic packaging that contains Talenti’s delicious product.

Recently, Talenti saw the need to expand their original Texas-based operation. After their search for co-packers who could meet their standards turned out fruitless, the company decided to take a different approach. Their focus shifted to Atlanta, GA, where they acquired a former ice cream plant and transformed it into another gelato production site. With a new site in place, Talenti found another need for a plastic container supplier that both was compliant to their stringent quality specifications and offered a great value.

That’s where CCC stepped in. We met the gelato maker’s needs by spending several million dollars on new special PET package-production equipment. We installed them in one of our three CCC facilities in the Atlanta area, our Fulton plant -- only 20 miles from our customer’s new production site.

Our supply chain solution provides millions and millions of high-quality, CCC manufactured plastic containers to Talenti each year. Through this continuity of supply, we are able to enable Talenti’s quickest possible time to market so they can continue guaranteeing happy spoons to their loyal customers.

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