Location: Olyphant, Pennsylvania USA
Completed: 2022
What We Completed
Roeslein teamed up with CANPACK to engineer, design, procure, and construct a state-of-the-art greenfield D&I plant in Olyphant, Pennsylvania – CANPACK’s first in North America. This facility boasts four fully automated canmaking lines and is CANPACK’s largest canmaking facility, to date.
What We Achieved
Throughout this landmark project, which marked CANPACK’s entry into the United States market and their largest can plant to date, Roeslein was entrusted with the critical design, manufacture, and installation scope. Despite the challenges of completing the project within the allocated time frame and budget, the team remained steadfast in their commitment to success.
The most significant achievement—and what we are most proud of—was delivering a high-quality facility that met all expectations, reinforcing CANPACK’s confidence in this milestone investment.
What We Did Differently
The project introduced several innovative solutions and advanced systems that enhanced both functionality and efficiency. The Mixed Label Inspection System underwent a complete redesign and implementation, ensuring improved accuracy and performance. For the first time in a CANPACK plant, the Pride spiral accumulation conveyance system was utilized, maximizing accumulation capacity within the facility’s limited space.
Additionally, a Pride single-lane gripper elevator and trackwork system were integrated to efficiently transport cans from the Belvac necker to the Torus gauge inspection system. The facility also featured a shared basecoater between Lines 1 and 2, optimizing resource utilization, and a robust nine bulk tank and pump skid system, supporting seamless operations across the plant. These advancements reflect the team’s commitment to innovative engineering and operational excellence.
What We Faced
A major obstacle during the Olyphant project was navigating the extended lead times for electrical parts, which had surged to as long as 48 weeks during the COVID era due to factory shutdowns and delayed deliveries. To keep progress on track, Roeslein’s manufacturing team was forced to ship equipment without motors and drives, which in turn caused delays in the installation phase. In response, Roeslein deployed additional manpower to expedite installation efforts and ensure line startup dates were met, demonstrating adaptability and resourcefulness in the face of significant challenges.
What We Learned
The biggest lesson we took away from this experience is that when unforeseen challenges arise, adaptability and creative problem-solving are critical. By identifying effective workarounds, we ensured that progress continued even in the face of adversity. This project reaffirmed the importance of collaboration, proactive communication, and flexibility in delivering results. Above all, we’ve learned that our success is inherently tied to our customer’s success—when they thrive, we thrive.
What We Heard
Our customer was impressed with how our team preempted problems and how smoothly the installation went, working with Roeslein. Having done this work many times, our Subject Matter Experts helped expedite the installation to make up for the lost time and get the job done in an efficient manner.
“No one in the world is able to supply the same level of quality, service, and scope like Roeslein. I specifically admire the way the Roeslein team reacts to emerging problems. We can always talk and find an acceptable solution for both sides. Projects change, sometimes a few times per week, but everything is always taken care of under Roeslein’s supervision.”
Kazimierz Maruszczak Head of Investment Department, CANPACK
How We Went Beyond the Ask
Roeslein went above and beyond by dispatching additional labor at our expense to mitigate delays caused by supplier equipment issues. Leveraging the expertise of our seasoned installation team, we accelerated the process to recover lost time. Drawing on our extensive experience in similar projects, we implemented efficient practices to ensure seamless progress, ultimately achieving customer satisfaction by upholding the highest standards of quality and performance.
