Killer Brownie Cuts Downtime with Packaging Automation
Watch the Killer Brownie Case Study Video
Challenge
Killer Brownie first connected with TPC Packaging Solutions at Pack Expo 2022. Their initial challenge was improving a manual packaging process where operators were hand-taping boxes across multiple product streams.
After implementing a Wexxar Bel semi-automatic case erector, the company streamlined box preparation for five packaging streams and improved consistency.
As production continued to grow, Killer Brownie faced a larger challenge in 2025:
- Frequent packaging-line downtime
- Limited floor space (approximately 10,000-12,000 sq. ft.)
- Multiple box sizes requiring constant adjustments
- Manual stacking and labeling operations
- Production losses of approximately $250 per minute of downtime
TPC Solution
TPC Packaging Solutions worked with Killer Brownie to design an “all-in-one line” focused on flexibility, automation, and future growth.
The solution included:
| Equipment / Solution | Purpose |
|---|---|
| Wexxar WF30 Auto Adjust | Automatically handles multiple box sizes with push-button changeovers. |
| Span Tech & Shuttleworth Conveyance | Efficiently moves product through the line while maximizing limited floor space. |
| Cantilevered Hand-Pack Station | Creates an ergonomic packing area without increasing the line footprint. |
| FANUC Case Palletizer | Automates stacking and palletizing in a compact footprint. |
Why Killer Brownie Chose TPC
Killer Brownie evaluated four different suppliers for the project. According to Matt Tye, Director of Manufacturing, the company ultimately selected TPC because of the strong relationship, responsiveness, and TPC’s ability to support both automation equipment and packaging consumables.
Before vs. After
| Metric | Before | After |
|---|---|---|
| Downtime per shift | Up to 90 minutes | 30 minutes or less |
| 16-count tray labor requirement | 26 people | 16 people |
| Throughput | Baseline | 25%+ increase |
| Box-size flexibility | Limited | Push-button changeovers |
| Palletizing | Manual | Automated |
Long Term ROI
Beyond labor and downtime savings, the line was designed for future scalability. The flexible box-handling capability has allowed Killer Brownie to accommodate different product configurations without investing in additional packaging equipment.
According to Matt Tye, the long-term return on investment could reach hundreds of thousands of dollars when considering labor savings, reduced downtime, and the ability to support future growth.
Ongoing Support
TPC’s involvement did not end at installation. Six months after implementation, the TPC team continues to provide support, coordinate OEM training when needed, and quickly resolve any issues that arise.
“The TPC team is transparent, approachable, easy to work with, and the knowledge and talent they have on site is second to none for me.”
— Matt Tye, Director of Manufacturing, Killer Brownie
Let's Build Your Next Packaging Solution
Every manufacturing operation has unique challenges. Whether you’re experiencing costly downtime, labor shortages, limited floor space, or increasing production demands, TPC Packaging Solutions can design a packaging system tailored to your operation.
Our engineers take a consultative approach to every project, helping you create a packaging line that can scale with your business.
Ready to see what’s possible? Contact our team today to schedule a consultation and start building a smarter packaging operation.
