How Truvant transferred two decades of European operational expertise to lead the end-to-end launch of a new contract packaging site in Dallas-Fort Worth — from site selection and construction to staffing, training, quality systems, and first production.
Program
Greenfield site launch & ongoing ops
Location
Dallas-Fort Worth
Facility
~335,000 sq ft
9,846 pallets
Year
2022
6 months
contract to commercial agreement
100%
delivery performance
3x
flex staffing ability for seasonality
A global consumer goods brand with an established European operation, expanding into North America for the first time. They needed a single partner to build and operate a US packaging facility from the ground up, without disrupting the existing supply chain or delaying market entry.
Entering North America from a European base is a structural problem, not a logistics one:
01
Site development
Selection, construction mgmt, equipment install, DFW config near DCs + Mexico supply.
02
Knowledge transfer
Two decades of EU lean/CI/quality systems transferred via the skills-exchange model.
03
Workforce & training
Dedicated training lead; quality-first culture — now the lighthouse training model.
04
Quality & safety
End-to-end QC/QA before commercial production; zero-incident safety standard.
05
Continuous improvement
S&OP + CI integrated from launch; OEE maximized from earliest runs.
100% OTIF
within first year
Zero quality defects
within first year
Supply-chain risk eliminated
(DFW DC proximity + Mexican base supply)
A replicable launch model
documented blueprint, now the lighthouse for NA expansion
What Truvant delivered wasn't a packaging service — it was operational infrastructure built in a market the client had never operated in, made possible by transferring two decades of lean, quality culture, and CI.
