Manufacturer
Flexing for Growth – How Prep Partners Helped a Manufacturer Expand Capacity Through Smart Pallet Management
A U.S.-based manufacturer of industrial raw materials was facing a critical bottleneck: limited warehouse space was holding back their ability to scale production. With raw materials arriving weekly via overseas shipments, their internal warehouse was becoming overwhelmed. Pallets intended for gradual production use were taking up space needed for new machinery and labor efficiency improvements.
The company needed a partner who could not only store their raw materials but also provide fast, reliable access to those materials on a weekly basis—while giving them accurate inventory data and logistics coordination.
They found that partner in Prep Partners Group.
Challenges
Limited storage space at their production site
Inability to scale up production due to raw materials crowding operational zones
Need for flexible pallet storage and accurate weekly release to align with production schedules
Desire to add new customers and increase manufacturing throughput, but constrained by space and labor allocation
The Prep Partners Solution
Prep Partners delivered a tailored pallet-in/pallet-out logistics program that included:
Inbound Freight Management
Oversaw the receipt and drayage of international containers directly to PPG’s facility. Handled oversized, non-standard pallet dimensions with no issue.Weekly Production Release Program
Maintained accurate inventory of all raw materials. Each week, a pre-scheduled batch of pallets was delivered to the manufacturer in sync with their production needs—eliminating congestion.Accurate Inventory Visibility
Provided real-time inventory reports to support procurement forecasting and reduce stockouts or overstocking.Space Optimization
Freed up square footage at the customer’s facility for new production machinery and improved labor utilization, turning storage space into revenue-generating capacity.
Key Benefits
➡️ Scalable Storage
Started with 60 pallets, and grew to over 150 in rolling inventory, thanks to flexible warehousing capacity.
➡️ Smooth Weekly Flows
PPG’s quick turnarounds for weekly outbound deliveries kept production moving without interruption.
➡️ Operational Expansion
With space freed up, the manufacturer installed new equipment, increased throughput, and took on two new customers within six months.
➡️ Inventory Accuracy
Consistent reporting allowed for better demand planning and procurement, reducing waste and downtime.
➡️ Oversize-Ready
PPG’s ability to handle oversize pallets removed the hassle of custom storage solutions or extra handling.
Looking Ahead
The manufacturer plans to increase their weekly pallet movement to 50+, with the expectation of maintaining a rolling inventory of 200+ pallets by Q2 next year. With Prep Partners, they have a logistics model that grows alongside their production capabilities—and clears the way for innovation.
Summary
Prep Partners Group gave this growing manufacturer the breathing room—and the logistical muscle—they needed to scale. With flexible pallet storage, fast turnarounds, and integrated inventory reporting, PPG unlocked both operational efficiency and new revenue opportunities.
"Partnering with Prep Partners has removed a lot of our growing pains by allowing us to scale up our raw material ordering without worrying about where to put it all.
Prep Partners reacts quickly to our requests and has made accommodations for our different units of measurement and unique pallet/product sizes.
With the imports having longer and longer lead times, being able to warehouse our products respective to the supply challenge has been a great success in ensuring we never run out of product for our customers.”
— Jaeger USA, Inc. Kevin Burr - Supply Chain Manager
