This Global Manufacturer Nearly Doubled Their Speed to Market for a Groundbreaking Product

In a fast-evolving manufacturing landscape, companies racing to meet market demands all face a shared challenge: achieve rapid, reliable production that won’t compromise on quality.

When a European-based manufacturer set out to launch a new product line, they also wanted to meet an unprecedented speed-to-market goal. But for their bold plan to work, they needed a responsive partner who could rapidly develop a highly specialized manufacturing solution—while the product design was still being finalized. Enter Delta ModTech.

Challenge

With innovation at the core of their business model, this European manufacturer had collaborated with plenty of machine developers in the past.

But for this project, “We wanted to do it faster and better than we ever did before,” says a senior vice president (SVP). “And we knew if we partnered with a run-of-the-mill equipment developer, it would slow us down. This was all about high-speed web handling.”

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“We knew if we partnered with a run-of-the-mill equipment developer, it would slow us down. This was all about high-speed web handling.”

Manufacturer Senior Vice President

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In fact, the project challenges were multifaceted:

• Condense the R&D and production phases to expedite the launch.
• Develop machine and production line solutions while product specs continued to evolve.
• Ensure the process could achieve high throughput rates, maintain tight tolerances, and meet demanding quality standards.
• Support multiple product types with seamless changeovers to future-proof the investment.

The manufacturer embarked on a search that eventually narrowed the field to what the SVP calls “the three best web handling companies globally.” From there, each candidate was subjected to an intense assessment process. 

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“Delta ModTech came out head and shoulders above the other companies.”

Manufacturer Senior Vice President

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The results? “I’m just telling you the truth and being factual: Delta ModTech came out head and shoulders above the other companies that we assessed,” he says.

Solution

A significant portion of Delta ModTech’s business comes from overseas clients, so the transatlantic relationship that formed between this manufacturer and Delta ModTech was hardly a rarity. But from the manufacturer’s perspective, the solutions Delta ModTech delivered proved to be exceptional in a number of ways:

An aggressive response to the timeline—from the very start

Delta ModTech prioritized every step of the process to ensure the client’s ambitious timeline stayed on track. In fact, according to the manufacturer SVP, this was apparent even during the selection process.

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“Delta had designed the equipment and got into procurement and mechanical build before other companies.”

Manufacturer Senior Vice President

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“Delta had designed the equipment and got into procurement and mechanical build before other companies had been through the legal review of the URS! So that just really talks to the speed that we were able to move forward on the project with Delta.”

An adaptable partner who “embraced” change and ambiguity

The product actually changed more than 30 times—both minor and major changes—over the course of the project.

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“Where other equipment builders are scared of ambiguity and constant change, I can really say with gusto that it’s something Delta embraced.”

Manufacturer Senior Vice President

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But the SVP says Delta ModTech’s engineers had the ability to keep pace with the dynamic product design process. “So, where other equipment builders are scared of ambiguity and constant change, I can really say with gusto that it’s something Delta embraced. And it really contributed to the success of the project.”

An automated production trifecta of “flexibility, performance, and quality”

Working closely with the manufacturing team, Delta ModTech designed a flexible yet fully automated production line with high-speed laser cutting, which, among other advantages, allows for rapid changeovers.

Moreover, that 100% automation enables assembly for incredibly tight tolerances and, in turn, exceptional product quality. The production line also includes 100% vision inspection for more than a dozen quality metrics, guaranteeing reliability at scale.

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“…flexibility, performance, and quality are all achieved at the same time.”

Manufacturer Senior Vice President

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“Very importantly,” says the SVP, “flexibility, performance, and quality are all achieved at the same time.”

Throughput

By working with Delta ModTech, the manufacturer has been able to achieve results like these:

Nearly 2X the speed to market compared to conventional machine developers

In the SVP’s experience, the time-consuming proof of principle steps that traditional equipment builders want to do “can almost double the delivery time.”

“So, we didn’t do that this time,” he says. “We just knew we had a good product concept. We knew that Delta was a good partner. We got our sleeves rolled up, and we just made it work, together.”

Production output that’s “orders of magnitude” greater than other options

The manufacturer has achieved production rates that were previously unthinkable for their product category.

Using Delta ModTech’s high-speed web machines has enabled them to achieve “very high throughputs, orders of magnitudes greater than any injection molded plastic devices,” says the SVP.

A production consultant to help position them for the future

Delta ModTech’s engineers have developed a deep grasp of the manufacturer’s product line, generating both short- AND long-term benefits.

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“I don’t think we would’ve had half the success that we’ve had if it hadn’t been that we partnered with Delta.”

Manufacturer Senior Vice President

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“It got to a point—and we’re still in that relationship now—that Delta was able to advise on a better manufacturing approach,” says the SVP. “This has helped us build in better future flexibility around other changes we might want to do.”  

A Final Note on Maintaining Customer Confidentiality

This case study reflects a common request from our customers: to maintain confidentiality. At Delta ModTech, confidentiality isn’t just a practice—it’s a cornerstone of our customer relationships. Every year, hundreds of manufacturers in competitive industries trust us to tackle their toughest challenges and to safeguard their strategic interests.

While some customers are happy to share their names, they represent less than half of our business. For others, confidentiality is critical—and it’s a responsibility Delta ModTech takes seriously to ensure your complete satisfaction.

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