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In the food and beverage industry, the ability to produce multiple product formats or varieties on the same line is becoming a major competitive advantage. A multi-product line not only enables quick adaptation to market demands, but also maximizes the use of existing equipment.

However, making this transition requires careful planning and well-informed technology choices. This article walks you through the key steps to shift toward a multi-product line while ensuring performance, profitability, and scalability.

Why Transition to a Multi-Product Line?

Evolving consumer preferences, pressure from retailers, and the drive for operational efficiency are pushing many food processing facilities to adopt more flexible solutions.

A well-designed multi-product line offers the ability to:

• Reduce format changeover times,

• Minimize production downtime,

• Handle different product types or packaging formats without multiplying dedicated lines,

• Increase agility in the face of shorter go-to-market cycles.

Before You Start: The Right Questions to Ask

To assess the feasibility of a multi-product line, consider the following key questions:

1. What types of products will share the line?

Dry or fresh goods? Rigid or flexible packaging? Compatibility between products (size, container type, inspection requirements) will dictate how the line is designed.

2. What throughput and production volumes are expected?

The equipment must handle production demand without compromising quality. It’s crucial to anticipate peak volumes and future capacity needs.

3. How many formats or recipes will be alternated?

The greater the variety, the faster and more reliable your automation and mechanical adjustments need to be.

4. What impact is expected on cost and productivity?

A technical audit will help identify bottlenecks, current performance losses, and continuous improvement opportunities.

During the Transition: Overcoming Technical Challenges

Shifting to a multi-product line in a food processing facility means balancing performance, hygiene, and flexibility. Key challenges include:

• Automating format changeovers

Adjustable conveyors, product recognition systems, and multi-format robotic handling can drastically reduce changeover time.

• Synchronizing equipment

Consistency between dosing, packaging, inspection, and palletizing modules is critical. A centralized control interface helps ensure seamless coordination.

• Training operators and technicians

Flexible lines are also more complex. Supporting teams in learning new technologies ensures better performance and fewer errors.

• Ensuring traceability and compliance

With greater product diversity comes a higher risk of labeling or product mixing errors. Vision systems, barcode readers, and MES software are strongly recommended.

Maximizing Return on Investment (ROI)

A multi-product line is a strategic investment. To get the most value:

• Choose modular equipment : Scalable systems are easier to adapt to future needs.

• Use data analysis tools: Track key performance indicators (OEE, downtime, actual throughput).

• Plan proactive maintenance: Prevent unplanned downtime and extend equipment life.

• Optimize internal flows: Line design should minimize movement, product crossovers, and idle time.

Storcan’s Expertise: Your Partner in Building a High-Performance Flexible Line

For over 45 years, Storcan has supported North American food and beverage  processing plants in transforming their production lines.

Our approach stands out for its:

• Custom solutions tailored to your environment, products, and industrial constraints,

• Recognized expertise in multi-product and multi-format lines,

• In-house manufacturing of robust, hygienic stainless-steel conveyors,

• Full project lifecycle management – from audits and integration to training and maintenance.

Not sure where to start?

We offer full line audits to assess feasibility, identify areas for improvement, and design the best solution for your operational reality.

 Explore our project success stories: Case Study

Looking to Increase the Flexibility of Your Production Line?

Contact our experts to discuss your project and discover how Storcan can help you build a flexible, high-performance, and cost-effective production line.