Industry Served | Glass & Clay
PalletView Unifies 16 Glass Manufacturing Facilities Across North America, Driving $5 Million in Annual Savings
250,000+
Sq. Ft. Facility Space Reclaimed
16
Locations Managed in Real Time
1
Consolidated PalletView Database
SNAPSHOT
Industry Served: Glass & Clay
Products/Services Provided: PalletView Software, Vendor Managed Inventory, Repair & Return Programs
Challenge
A major glass packaging manufacturer faced growing inefficiencies in its returnable packaging system across the U.S. and Canada. With limited visibility between sites, valuable space was wasted, replacement costs climbed and operational data lived in silos.
Solution
Millwood created and implemented PalletView, a comprehensive, real-time inventory tracking software, to unify this customer’s returnable packaging program and connect all 16 of their facilities under a single database.
Results
By integrating operations across North America, the customer reclaimed more than 250,000 square feet of usable space, reduced pallet and packaging waste and achieved annual cost savings exceeding $5 million.
A Growing Network, A Mounting Challenge
For years, this glass manufacturer had managed returnable pallets region by region, with each facility using its own tracking spreadsheets and manual reporting systems. As the company grew, so did the complexity of its logistics network. Pallets moved between customer sites, warehouses and repair centers without a unified tracking method.
What started as an incentive to contribute to their circular system – packaging returns in exchange for credit – became a fragmented process burdened with excess freight, lost assets and mounting replacement costs. While some facilities received more returns than they could handle, others faced shortages and were forced to purchase new packaging materials at great cost; both issues hampered our customer’s drive for intra-network sustainability.
When they first came to us, the customer described how facilities that should have been maximizing production space were instead forced to store tens of thousands of square feet of unused or unaccounted pallets. To compound the problem, a lack of standardization in the returns process sometimes led to inaccurate, haphazard reporting about the number and quality of units returned, adding further administrative strain and confusion.
When Success Outgrew the System
The company’s leadership recognized that continuous growth would depend on their ability to scale smarter. They needed a way to manage assets across borders, track performance in real time and eliminate redundant purchasing. The existing model, dependent on regional management and disconnected systems, simply couldn’t keep up.
We were brought in to evaluate operations across all 16 facilities. What we discovered was not a lack of effort, but a lack of integration: each location had its own data set, its own version of “the truth.” Without a centralized view, the business couldn’t reliably report how many pallets were in circulation, how efficiently they were being used and how accurately credit receipts were being issued.
Building a Single, Sustainable Source of Truth
Our custom solution started with PalletView, a proprietary Millwood software, initially developed specially for this client. PalletView helps companies track, manage and optimize their returnable packaging assets. We configured the software to consolidate all of our customer’s facility-level data into one-cloud based platform, providing real-time visibility across every location in North America.
Millwood paired this innovation with hands-on operational support. Repair-and-return processes were standardized, Vendor Managed Inventory programs were synchronized and data reporting was unified. For the first time, leadership could view asset performance, repair cycles and cost recovery metrics through a single dashboard.
PalletView further empowered this glass manufacturer to embrace their circular economy goals. They can now hold their customers accountable through a single operational hub that bridges the gap between production, logistics and ESG reporting.
Turning Complexity Into Clarity
With Palletview in place, the manufacturer quickly saw measurable improvements. Space occupied by disorganized pallet stacks was reclaimed for production, freeing more than 250,000 square feet across their network. Tracking accuracy improved exponentially, enabling better planning and reduced downtime.
The unified database allowed the company to optimize repair cycles, minimize over-ordering and ensure that every pallet was used to its full lifecycle potential. Administrative time spent reconciling data between sites was reduced dramatically, and the company’s leadership finally had the clarity needed to make sustainable, data-driven decisions.
These combined efficiencies translated into more than $5 million in annual cost savings – a result of reduced waste, optimized freight, reclaimed space and standardized processes across all 16 North American locations.
Confidence Through Partnership
For Millwood, this success reflects the power of partnership, innovation and integration. By combining smart technology with hands-on service, Millwood helped transform a fragmented system into a streamlined, sustainable model that delivers measurable results year after year.
PalletView continues to serve as the customer’s foundation for returnable asset management – proving that clarity, collaboration and resource stewardship can work hand in hand to strengthen any supply chain.
We aim to serve every Millwood customer with measurable results like these.
Connect with a PalletView specialist to explore how visibility and integration can help your business simplify, standardize and save.
Connect With an Expert Today
We understand that time is one of your most valuable assets; that’s why we work hard to provide every one of our clients with a systems-based approach to improving quality and reducing costs while increasing efficiency. Whether you are looking for a single product or need a more comprehensive solution, our business is to support and serve the needs of your business.
We work with each of our clients to:
- Listen to their current and upcoming needs.
- Determine which of our products and services fit their application best.
- Develop an integrated plan to help them succeed.
We look forward to talking with you to learn how our team can serve your business.
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When a fast-food giant faced a packaging error that threatened its automated distribution center, Millwood’s Packaging Science Lab stepped in to redesign, test and validate new pallet configurations- saving 136,000 boxes of product and ensuring an on-time launch.
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