The Hidden Cost of Cheap Parts—and How to Fix It

Customer Success Story: Food Distribution

One of the largest food service distributors and suppliers in the nation operates extensive conveyor systems to maintain the efficiency of its distribution operations. When a critical part in their conveyor system began failing repeatedly, the resulting downtime became a top concern for the maintenance team.

The turning point came when one of their Maintenance Managers began searching online for a solution. They discovered Cope Plastics and reached out. Our sales rep, Travis, returned the call and quickly built rapport—so much so that the Maintenance Manager saved his number in his phone. That conversation led to a site visit and a hands-on collaboration.

Challenge: A Critical Part That Couldn’t Keep Up

The part in question was a small but essential component used at multiple points within their conveyor system—tasked with redirecting product from one line to another at key transition points. It played a vital role in keeping items moving smoothly along the correct path.

In this case, their original manufacturer of this part discontinued making it, leaving them to resourcefully create the part in house. The in-house part could not stand up to the demands of full-time production and the regular failure of the in-house part would cause disruptions in their process resulting in un-planned down time on their system. Each failure halted the conveyor’s ability to reroute product, resulting in delays, added maintenance labor, and production slowdowns.

After closer evaluation, Cope Plastics in conjunction with their management, identified an opportunity to improve both the design and material. The original geometry included sharp internal angles, which created stress points under load. By reengineering the part with smoother transitions and selecting a more durable performance plastic, we were able to drastically improve its reliability and lifespan.

Solution: Smarter Design, Smarter Material

Travis and the Cope Plastics manufacturing team knew they could do better. Working with our Chandler and Goodyear locations, we created multiple prototypes from different materials—UHMW, nylon, and acetal—each with its own price point and performance profile. We supplied two of each version and encouraged their team to run their own 30-day performance trial.

All samples held up exceptionally well—none of the Cope Plastics versions failed during the trial. Ultimately, the team chose white acetal, balancing performance and budget. The critical improvement? Our engineers redesigned the part with a radius instead of a 90-degree corner, distributing stress more evenly and increasing durability. We also invested in creating CAD files and 3D models from scratch, since no technical drawings existed—providing the customer with a professional-grade, production-ready solution.

Although our part came with a higher upfront cost, the logic was clear: “If your parts are breaking every day, how much is that really costing you?” The investment in better design and material delivered unmatched ROI.

Result: From 10 Days to Over a Year of Runtime

The updated part lasted well over a year—the first prototype didn’t fail until over 12 months of heavy use, and even then, it was a machine malfunction that chipped the part, not a design flaw. The performance blew expectations out of the water.

Management’s feedback says it all: “Working with Travis and Cope Plastics has proven to be a success for our Maintenance Team. We continue to build our relationship by working together to develop or replace existing parts. Their Honesty, Integrity and Customer service is unmatched and has proven to be very beneficial to both our industries. We look forward to working with Cope Plastics for all our future needs.”

Despite initial concerns about cost, this distributor quickly realized that this was now the cheapest part on their machine—not because of price, but because of longevity and reliability. Maintenance time dropped dramatically, downtime was minimized, and productivity rose. This single part upgrade fundamentally improved line efficiency.

The True Cost of Downtime

While the original part seemed inexpensive, the hidden costs were significant:

• Estimated downtime cost per hour: $10,000

• Time to replace part: ~2 minutes

• Downtime cost per changeout: $167/min × 2 = $334.00

• Technician labor: ~$1.00

• Total cost per failure: ~$350.50

In 2025 alone, the food distributor had already replaced 79 divert parts, but after switching all units to the new acetal insert, the need for replacements dramatically dropped. Of those 79, roughly 45 would not have required replacement if the new part had been implemented from the start.

This solution transformed a $15 part into a major cost-saver—proving that the right material and design can pay for itself many times over.

Conclusion: Results-Driven Service With Old-School Customer Care

This project succeeded because Cope Plastics stayed committed to what we do best: selling results, not just parts. Travis and the team never wavered from that mindset. In fact, when another component failed due to poor fit, Travis had it reworked and returned within 45 minutes—classic, old-school service that makes a lasting impression.

Our takeaway?
Better design + better material = better results.

This project serves as a textbook example of how Cope Plastics helps food industry leaders solve complex problems with smart engineering, hands-on collaboration, and relentless service.