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Puls8 Replan Case Study

Boosting Supply Chain Agility for a Global Food Manufacturer

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A leading B2B supplier of pre-cooked meats, plant-based proteins, and sausage ingredient solutions operates advanced manufacturing facilities in Ireland, Germany, and the U.K., serving major food brands across 55,000+ retail and foodservice locations in more than 50 countries.

Despite their scale and operational sophistication, their ERP system could not deliver the planning intelligence needed to manage complex, multi-site production. As demand volatility increased, the company needed a faster, more agile approach to production planning.

Puls8 Replan delivered the solution.

The Challenge

Complex Manufacturing Environment

Strict brand and food safety standards—including allergen control, Halal certification, traceability, and animal welfare—require highly controlled production processes.

Multiple product formats (RTE, chilled, cupboard, and IQF) combined with advanced cooking technologies created a complex production network with numerous routings and constraints.

Manual planning made it difficult to evaluate changes or respond quickly to operational disruptions.

Volatile Demand

Demand patterns were highly unpredictable, with weekly fluctuations of up to 40% driven by last-minute customer orders. This volatility negatively impacted delivery performance and operational efficiency.

Inefficient Planning Processes

Production planning relied heavily on Excel and ERP tools, often requiring several days to produce a single plan. Limited scenario analysis meant planners spent most of their time reacting to issues rather than improving performance.

The Puls8 Replan Solution

After evaluating several planning platforms, the company selected Puls8 Replan for its proven results in the food and beverage industry and its ability to deliver value quickly.

Puls8 Replan is built specifically for complex food manufacturing environments and models real-world operational constraints, including:

  • Equipment capacity and line constraints
  • Multi-stage production processes
  • Allergen segregation and compliance requirements
  • Changeover sequencing

 

Inventory and fulfillment rulUsing advanced optimization algorithms, Puls8 Replan generates highly optimized production plans aligned with business priorities such as maximizing capacity, improving service levels, and reducing inventory.

The platform integrates directly with existing ERP systems and supports the company’s S&OP planning process, enabling faster decisions without disrupting core operations.

Implementation

Puls8 Replan was deployed on two critical production lines using the platform’s standard rapid deployment methodology.

The implementation required only one FTE day per week from the customer team and delivered results within eight weeks.

Key implementation steps included:

  • Planning process review and production line walkthroughs
  • Data validation and gap resolution
  • KPI alignment and improvement targets
  • Planner training and solution rollout
  • Ongoing scenario tuning and optimization support

Results

Within eight weeks of deployment, the company achieved significant improvements in planning speed, operational efficiency, and decision-making.

Production planning time

Reduced from 3 days to 30 minutes

Strategic CapEx planning

Reduced from weeks to days

Operational performance improvements

  • 6% increase in production volumes
  • 47% reduction in changeover time
  • 27% reduction in inventory levels

The organization is now on track for a €1M+ increase in contribution margin within 12 months.

Business Impact

Puls8 Replan transformed the company’s production planning process—moving teams from reactive firefighting to proactive optimization.

Planners now have the ability to quickly model scenarios, evaluate operational trade-offs, and make faster, more confident decisions.
The result is a more agile, resilient supply chain capable of responding to demand volatility while protecting brand standards.

Turn Supply Complexity Into Competitive Advantage

Puls8 gives you the intelligence to respond in real time, optimize operations, and build a more agile, resilient supply chain.

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