Find the margins you’re losing on the line.

Our work starts with the unmeasured losses you’ve learned to deal with: extra product in packages, quality drift, changeovers that crawl. We make these visible on every run, so you fix the problem instead of budgeting for it.

Talk to a consumer goods Insider

Three losses that hide inside a growing product mix

We look for efficiency beyond the line itself: inside the package, between changeovers, and in the utility bill. Uncovering these issues is the first step to greater throughput.

Small, unmeasured losses, like a little extra product in every package or a few percentage points of scrap are easy to miss on one line and expensive once they’re repeated across a dozen SKUs. GrayMatter connects what your check-weighers, fillers, and packaging equipment already record and delivers a real-time picture of what’s happening across production, from raw materials through packaging. Losses become visible and fixable instead of just accepted as the cost of running more variety.

Explore Brilliant Ops

It happens once at the time of the changeover itself, and again in the ramp-up afterward. GrayMatter modernizes automation and controls to make each changeover faster and more repeatable, so growing product mix runs at the throughput you planned for.

Explore Industrial Automation

Water, air, gas, electricity and steam usually get evaluated during production stoppages, which a high-demand plant rarely has. GrayMatter builds predictive analytics that watch utility use in-line, so operators can adjust as they run or plan production around swings in utility cost and demand.

Explore Approachable AI

Solutions for any product mix

GrayMatter works with consumer goods manufacturers managing growing product complexity — more SKUs, more frequent changeovers, and production increasingly built closer to where demand actually is.

High-mix, multi-SKU production operations

Real-time visibility built to keep pace with more product variations, run more often than these lines were originally designed for.

Changeover-intensive & rapid new-product introduction manufacturing

Automation and controls modernization that keeps line throughput up as changeovers become more frequent.

Regionalized & multi-site consumer packaged goods networks

Predictive analytics designed to prove out at one facility and reapply as production disperses closer to demand rather than staying centralized.

Packaged & specialty food and nutrition Manufacturing

Plant-level waste, quality, and energy visibility for producers of packaged food, dressings, sauces, and specialty nutrition products.

CPG Case Studies

View All
Industry Insight

Rick Bullotta, founder of ThingWorx and Lighthammer

The eye-opening power of IoT

ThingWorx founder Rick Bullotta on putting advanced analytics to work on downtime, quality and energy use.

“The thing to remember is that visibility is useful, but visibility without insight and action means you’re missing out.”

Read More

Let us define the losses on the line

Whether it’s a few pounds of overfill per shift or a paper-based quality process that’s overdue for an upgrade, GrayMatter’s consumer goods experts are ready to talk through where to start.

Talk with a Factory Advisor

FAQs

No — it’s designed to start at one facility. The value comes from proving the approach in one place first, then reapplying it at other sites once it’s shown results.

Yes, with modernization. GrayMatter makes a plan to modernize changeover-heavy lines so more product variety doesn’t mean more downtime.

Yes, and that’s often exactly where the biggest savings come from. Predictive analytics and digital twins regularly surface losses — like overfill or in-line quality drift — that go completely unmeasured under manual or periodic tracking.

It doesn’t change the approach — if anything, it’s exactly the situation this is designed for. We prove a model at one facility, then reapply it as production disperses across more, smaller sites.

Yes. Predictive analytics can be applied to energy consumption the same way it’s applied to production quality — surfacing real-time cost and demand fluctuations instead of relying on periodic manual checks.