Manufacturing Operations | Industrial Consulting

PET Manufacturing Startup: Zero-to-One Operations Launch

Complete Industrial Setup & Operational Launch | Saudi Arabia, 2019-2020

Transformed a greenfield concept into a fully operational PET manufacturing facility within 12 months, establishing vendor partnerships, operational teams, and governance frameworks that delivered immediate production efficiency and sustained growth.

Project Overview

Client Type

Greenfield PET Manufacturing Startup

Location

Saudi Arabia

Timeline

18 months (2019-2020)

Role

Lead Operations Consultant

Scope

Complete manufacturing setup from concept to operational launch, including facility design, vendor management, team building, and governance implementation.

The Challenge: Building from Nothing

Our client faced the ultimate greenfield challenge: establishing a PET manufacturing operation from absolute zero. With no existing infrastructure, vendor relationships, or operational team, they needed to achieve market entry within an aggressive timeline while ensuring cost-efficiency and regulatory compliance in the Saudi Arabian market.

No Foundation

Zero existing plant infrastructure, vendor relationships, or operational processes

Tight Timeline

Aggressive market entry deadline in competitive PET manufacturing landscape

Cost Efficiency

Need for scalable, cost-optimized operations from day one

Compliance

Full regulatory compliance requirements in Saudi Arabian industrial market

Strategic Approach: Four-Pillar Implementation

01

Plant Layout & Design

  • Capacity-optimized facility design for 50,000 bottles/day
  • Production flow optimization across 15,000 sqm footprint
  • Safety and regulatory compliance integration
  • Future expansion considerations built-in
02

Vendor Ecosystem Development

  • Comprehensive vendor sourcing and evaluation
  • Bill of Materials (BoM) cost optimization
  • Strategic partnership negotiations
  • Supplier risk assessment and backup plans
03

Team Building & Training

  • Operations team recruitment and structure design
  • Skills assessment and comprehensive training programs
  • Leadership development for local managers
  • Knowledge transfer and process documentation
04

Governance & SOPs

  • Standard Operating Procedures development
  • Quality control frameworks implementation
  • Performance monitoring systems setup
  • Daily/weekly/monthly operational rhythms

Results: Operational Excellence from Day One

12 months

Operational Launch

From concept to full production

15%

Cost Savings

Through vendor optimization

Zero incidents

Safety Record

First year operations

98%

Production Efficiency

Target rate achieved

6 months

Team Autonomy

Local management transition

100%

Regulatory Compliance

All approvals on schedule

Supporting Evidence & Documentation

Plant Layout Schematic

Raw Materials Storage
→
Polymerization Unit
→
Preform Injection
→
Bottle Blow Molding
→
Quality Control
→
Packaging
→
Finished Goods
Capacity: 50,000 bottles/day
Footprint: 15,000 sqm
Safety zones integrated

Vendor Management Dashboard

Category
Vendors
Status
Savings
Raw Materials
Vendor A (PET Resin), Vendor B (Additives)
Contracted
12%
Equipment
Vendor C (Injection), Vendor D (Blow Molding)
Contracted
18%
Packaging
Vendor E (Labels), Vendor F (Caps)
Qualified
8%
Logistics
Vendor G (Transport), Vendor H (Warehousing)
Contracted
20%

Bill of Materials (BoM) Optimization

Material
Before
After
Savings
PET Resin (Grade IV+)
$1.45/kg
$1.28/kg
12%
Preform Molds
$45,000/set
$38,000/set
16%
Blow Molds
$32,000/set
$27,500/set
14%
Packaging Materials
$0.08/unit
$0.07/unit
13%

Governance Rhythm Calendar

Daily

Production Status Review (7:00 AM)
Safety Check Rounds (2:00 PM)
Quality Control Reports (6:00 PM)

Weekly

Team Performance Meeting (Monday 9:00 AM)
Vendor Performance Review (Wednesday 2:00 PM)
Financial KPI Review (Friday 10:00 AM)

Monthly

Strategic Planning Session (1st Friday)
Regulatory Compliance Audit (2nd Wednesday)
Vendor Relationship Review (3rd Tuesday)

Quarterly

Board Performance Review
Annual Planning & Budget
Strategic Vendor Negotiations

Standard Operating Procedures (SOP) Sample

SOP-001: Production Line Daily Startup Procedure

Version 1.0 | Effective Date: January 2020 | Review Date: January 2021
1
Safety Equipment Check

Verify all personnel wearing required PPE

2
Equipment Inspection

Visual check of all machinery for damage/wear

3
Raw Material Verification

Confirm material quality certificates

4
Process Parameter Setup

Set temperature, pressure, and speed parameters

5
Test Run Execution

Run 10-unit test batch for quality verification

6
Quality Approval

QC manager approval before full production

7
Production Commencement

Begin full-scale manufacturing operations

Transformation Achieved

This engagement demonstrates the complete transformation of an abstract business concept into a thriving, efficient manufacturing operation. From zero infrastructure to a fully operational facility producing 50,000 bottles daily, we established not just the physical plant, but the entire operational ecosystem required for sustained success.

The sustainable operational model we implemented continues to drive growth and profitability, with the local management team now fully autonomous and the governance frameworks ensuring consistent performance and continuous improvement.

Ready for Your Next Manufacturing Challenge?

Specialized in zero-to-one industrial operations setup, vendor ecosystem development, and sustainable manufacturing governance frameworks.