Case Studies

Digital Spare Parts Transformation for Beverage Packaging Plant – Greece

Client

Leading Beverage Packaging Facility, Greece

Industry

Food & Beverage Manufacturing

Project Duration

12 Months

Solution Provider

MORSAN – Digital Spare Parts & Additive Manufacturing

Issue: High Spare Part Costs and Long Lead Times

The client faced persistent operational inefficiencies due to 15 critical spare parts that required frequent replacements.

Long lead times of 3–5 weeks per order

Risk of production delays

High unit costs

(€70 per spare)

Limited part availability & vendor dependency

Annual usage

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.

What we asked and what we delivered

On-Demand Spare Part Manufacturing

MORSAN introduced a digital spare parts program using advanced additive manufacturing techniques and engineering-grade polymers. The transformation included:

🛠 Redesign all 15 spare parts

Optimized for 3D printability and durability.

📐 Digital CAD archive

Ready for on-demand production.

🖨 Onsite 3D printing

Instant spare part production.

🧪 Material optimization

Industrial polymers for strength & wear resistance.

12-Month Impact & Results

Operational Benefits

💰 Drastic cost reduction

Significantly lowers spare part procurement expenses.

📦 Inventory optimization

Local, on-demand production reduces stock needs.

⏱ Lead time compression

From weeks to hours, maximizing uptime.

📈 Scalable digital catalog

Easily expand your spare parts library digitally.

Conclusion

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.

CASE STUDIES