Client: Leading Beverage Packaging Facility, Greece
Industry: Food & Beverage Manufacturing
Project Duration: 12 months
Solution Provider: MORSAN – Digital Spare Parts & Additive Manufacturing
The client faced persistent operational inefficiencies due to 15 critical spare parts that required frequent replacements. Key issues included:
Long lead times of 3–5 weeks per order, risking production delays.
High unit costs, averaging €70 per spare.
Limited part availability and vendor dependency.
Annual usage of approximately 200 units per part.
Total annual spare parts cost: €90,500.
These constraints resulted in increased downtime risk, higher inventory overhead, and a heavy reliance on external suppliers.
MORSAN introduced a digital spare parts program using advanced additive manufacturing techniques and engineering-grade polymers. The transformation included:
Redesigning all 15 spare parts for 3D printability and durability.
Creating a digital CAD archive for future on-demand production.
Onsite 3D printing capability for instant spare part production.
Material optimization using industrial polymers tailored for mechanical strength and wear resistance.
| Category | Before MORSAN | After MORSAN | Improvement |
|---|---|---|---|
| Unit Cost per Spare Part | €70 | €12 | -82.16% |
| Annual Cost (200 pcs per part) | €14,300 | €2,400 | -€11,900 |
| Total Annual Spare Parts Spend (15 parts) | €90,500 | €50,120 | -€40,380 (44.6%) |
| Average Lead Time | 3–5 weeks | < 48 hours | 90% faster |
Drastic cost reduction in spare part procurement.
Inventory optimization through local, on-demand production.
Lead time compression from weeks to hours, improving uptime.
Scalable model for expanding the digital spare part catalog.
The partnership with MORSAN enabled the beverage packaging plant to modernize its maintenance strategy, minimize downtime risk, and achieve significant operational savings. This case exemplifies the value of digital inventory and additive manufacturing in industrial environments.