Programs that shipped. Results that held.

Engineering outcomes from live operations. Client names published as approvals land — the engineering is on the record now.

§ CASE 01 / ARMORPALLET

Wood pallets were breaking the automation line.

Armorpallet 1050 × 950 · A global beverage producer · United States

Relationship
PTM client 3–5 years

Program
12–18 months to production

The problem

Pallets breaking in operation, incompatible with automated handling, and carrying hygiene and contamination risk. The client was running wood pallets — failing from forklift impact damage and dimensional inconsistency the automation couldn't tolerate.

What PTM engineered

Armor block technology adapted to the client's dimensions: structural reinforcement in the columns and blocks, with tolerances engineered for automated handling. A custom-engineered program — CAD design, prototype, pilot run — carried from business case to production in 12–18 months.

200–600 trips

Service life

Source: independent lab testing of this exact product — Virginia Tech, Center for Packaging and Unit Load Design, 2023 (FasTrack protocol; Armor 1050 × 950).

Stoppages reduced

Line reliability

Source: measured at the client's operation, by the client.

Lower carbon footprint Program still running today

§ CASE 02 / ULTRAPALLET

Wood breakage and replacement cost, on a high-volume line.

Ultrapallet 1220 × 1100 · A global brewing group · high-volume brewing operation

Relationship
PTM client 10+ years

Program
12–18 months to production

The problem

Pallets breaking in operation with replacement cost running too high. The client was on wood pallets — failing from forklift impact damage, with a replacement rate the business case couldn't sustain.

What PTM engineered

A footprint matched to the existing line so it runs unchanged, structural reinforcement in the columns for forklift impact, and weight reduction. Proven through a pilot run, carried from business case to production in 12–18 months.

75–90%

Damage / breakage reduction

Source: measured at this client's operation, by PTM.

Under 25%

Replacement rate reduced to

Source: measured at this client's operation, by the client.

Damaged units recycled into new ones Lower carbon footprint

§ CASE 03 / ULTRAPALLET

Displacing another plastic supplier that kept failing.

Ultrapallet 1220 × 1100 · A global brewing group · high-volume brewing operation

Relationship
PTM client 10+ years

Program
6–12 months to production

The problem

High replacement cost and product damage in handling. The client was running another plastic supplier's pallets — failing from forklift impact damage.

What PTM engineered

A footprint matched to the existing line and structural reinforcement in the columns. Proven through a pilot run into full production, carried from business case to production in 6–12 months.

25–50%

Damage / breakage reduction

Source: measured at this client's operation, by the client.

Under 25%

Replacement rate reduced to

Source: measured at this client's operation, by PTM.

Damaged units recycled into new ones Lower carbon footprint Program still running today

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