The ROI of SmartSkin – Real Numbers from Leading Manufacturers
Investing in SmartSkin’s diagnostic and optimization technology is not just about improving efficiency—it’s about unlocking significant cost savings, increased production output, and improved product quality. Whether you’re in beverage, food, or pharmaceutical manufacturing, the right data can transform your bottom line.
But how much does SmartSkin really save? Let’s look at real-world numbers from top manufacturers that have integrated SmartSkin into their high-speed production lines.
1. Reducing Product Waste-more than $500K Saved Annually
Waste is one of the biggest hidden costs in production. Whether it’s damaged cans in beverage lines, crushed packaging in food processing, or rejected pharmaceutical batches due to improper handling, every defective product represents lost revenue.
By using SmartSkin’s real-time force and pressure diagnostics, manufacturers can pinpoint exactly where damage occurs- preventing further waste.
Real Results using SmartSkin
- Diagnosing the root cause of leakers that helped reduce QA holds by 77%
- A pharmaceutical plant using SmartSkin to monitor vial handling cut breakage rates by 70%, leading to $350K in annual savings.
2. Maximizing Line Speed – $300K+ in Additional Revenue
In high-speed production, every second matters. Running at suboptimal speeds due to fear of product damage or machine failures leads to massive revenue loss over time. SmartSkin allows manufacturers to identify and correct speed-related damage points so they can safely increase line speeds without compromising quality.
Real Results using SmartSkin
- A major beverage company increased filler speeds by 8% after using SmartSkin to optimize pressure settings, resulting in an additional $300K in revenue per year.
3. Cutting Equipment Maintenance and Downtime Costs
Unexpected downtime can cost manufacturers hundreds of thousands of dollars per year. Many stoppages occur due to undetected mechanical stress, misalignments, or excessive wear on equipment. SmartSkin allows maintenance teams to predict failures before they happen, reducing downtime and eliminating unnecessary service calls.
Real Results using SmartSkin
- A beverage manufacturer using SmartSkin to monitor sidewall pressure in its canning line prevented a catastrophic seamer failure, avoiding a $200K+ emergency repair.
- A global brewery extended its filler and seamer lifespan by 20%, reducing spare part costs and eliminating three major service calls per year.
- A pharmaceutical manufacturer enhanced their fill-finish operations and reduced rejection & downtimes while elevating data integrity standards
4. Reducing Vendor Service Calls – $100K+ Saved on External Support
Many manufacturers rely on third-party vendors to diagnose and resolve line issues. These service calls are expensive, time-consuming, and often delay production for hours or even days. SmartSkin equips in-house teams with actionable data, reducing the need for external technicians.
Real Results using SmartSkin
- A multinational beverage company reduced its reliance on OEM service calls by 40%, saving over $100K in annual fees.
The Bottom Line: Saving with SmartSkin
The total potential ROI of using SmartSkin is approximately 10 times its first year cost making it an investment that easily pays for itself in as little as 2 months of a purchase. Countless times it has boosted yields and quality for our clients, reducing their rates of rejects and defects. It provides both short-term and long-term benefits to where plants can use it for reactive diagnostic measures but also to set-up proactive processes that ensure the elimination of unplanned downtime. It has been unperturbed in improving efficiency without interrupting production.
If you would like to know how much you can save using SmartSkin’s Technology
Contact us today for a custom ROI calculation.
