Beige capsules illustrating unseen inefficiencies manufacturers face and how AI helps recover lost time and resources.
Beige capsules illustrating unseen inefficiencies manufacturers face and how AI helps recover lost time and resources.
Beige capsules illustrating unseen inefficiencies manufacturers face and how AI helps recover lost time and resources.

How Impermea Materials Cut an 8-Week Delay in Half While Scaling a New Facility

How Impermea Materials Cut an 8-Week Delay in Half While Scaling a New Facility

Lead Time Recovery
Lead Time Recovery

8 weeks reduced to 4

8 weeks reduced to 4

Cash Flow Improvement
Cash Flow Improvement

60-day payment terms unlocked

60-day payment terms unlocked

60-day payment terms unlocked

Facility Scale-Up
Facility Scale-Up

Boston to NC without supply chain disruptions

Boston to NC without supply chain disruptions

Boston to NC without supply chain disruptions

"Tenkara gave us the visibility we didn't know we were missing. We went from hoping suppliers would come through to knowing exactly what our options were - before problems hit."

"We were moving our entire factory and nervous about supply chain chaos. Our customers were already frustrated - we couldn't handle any more delays. Tenkara found suppliers that didn't just match our old lead times, they actually cut them down on our core PFAS-free products. Literally saved our asses."

David Zamarin
Founder, Impermea Materials

THE CHALLENGE

Scaling manufacturing while fighting unexpected supply chain chaos

Scaling manufacturing while fighting unexpected supply chain chaos

Impermea Materials is solving one of the hardest problems in chemical manufacturing: replacing toxic PFAS chemicals with high-performance, sustainable alternatives. Their coatings protect food packaging, textiles, and healthcare materials - without poisoning people or the planet.

The science is hard. The operations? Complex.

David and his team had just relocated from Boston to North Carolina, opening a new production facility to meet surging demand for PFAS-free solutions. New building. New equipment. New supply relationships. Everything had to work - at scale - immediately.

Then a critical material supplier dropped the news: what was supposed to be a 2-week lead time was now 8+ weeks. No warning. No alternatives offered. Just "sorry, we're backed up."

For a chemical manufacturer ramping a new facility, this put business and decade long relationships at risk:


Production planning in freefall - couldn't package finished product, couldn't fulfill orders


No supplier alternatives mapped - they'd relied on established relationships from Boston


Cash flow squeeze - new facility expenses while unable to ship finished goods


Customer commitments at risk - B2B customers don't wait; they find other suppliers


Zero visibility into when it would resolve - supplier kept pushing the date back

Impermea had the technology, the facility, and the demand. What they didn't have was the operational infrastructure to see problems coming and pivot fast when suppliers failed.

THE SOLUTION

Tenkara agents turned an 8-week disaster into a 4-week miracle

Tenkara agents turned an 8-week disaster into a 4-week miracle

Impermea deployed Tenkara mid-crisis and immediately put multiple agents to work:


Delay Detection Agent: Started continuously monitoring the problematic supplier's communications and lead time trends. Within days, flagged that the "8-week" estimate was actually trending toward 10+ weeks based on supplier behavior patterns. This early warning let David start planning around an even worse scenario.


Alternative Supplier Agent: Immediately began sourcing and vetting alternative packaging suppliers who could meet Impermea's specialized requirements (chemical compatibility, FDA compliance, sustainable sourcing). Within 72 hours, Tenkara had identified three qualified alternatives - two of whom could deliver in 4 weeks.


Quote Acceleration Agent: Coordinated simultaneous outreach to all three alternatives with detailed specs. What would normally take David two weeks of back-and-forth emails happened in three days. Competitive quotes in hand, real options to evaluate.


Credit Terms Agent: While David was focused on solving the immediate delay, Tenkara's credit agent was working in the background - identifying suppliers willing to offer extended payment terms and automatically applying for 60-day terms on David's behalf.


The credit terms play was crucial: New facility meant capital was tight. Being able to receive materials now and pay in 60 days instead of net-30 gave Impermea breathing room to ramp production without a cash crunch.


Compliance Validation Agent: Cross-checked all alternative suppliers against Impermea's stringent requirements - FDA compliance, chemical compatibility testing, sustainability certifications. Eliminated suppliers who looked good on paper but would fail in practice.

STRATEGIC EXECUTION

Cut the 8-week delay in half by pivoting to alternative supplier

Unlocked 60-day payment terms, improving cash flow during facility scale-up

Built redundancy into the supply chain so one supplier failure never threatens production again

Gave David his time back to focus on chemistry and customer relationships, not vendor crisis management

THE RESULTS

From bottlenecked to bulletproof in one month

From bottlenecked to bulletproof in one month

Since implementing Tenkara during their facility launch, Impermea transformed a near-disaster into a competitive advantage:

8-week delay cut to 4 weeks - alternative supplier sourced and qualified in 72 hours

60-day payment terms unlocked - $10K in improved working capital during critical ramp period

3 backup suppliers mapped for every critical material - redundancy built into the system

Zero production delays since initial crisis - early warning system prevents surprises

12+ hours weekly saved - David's time redirected from procurement firefighting to R&D and sales

The moment that defined it

The moment that defined it

Four weeks into the original 8-week delay, David's primary supplier called with more bad news: actually going to be 10-12 weeks. But David wasn't panicking anymore.

"I told them 'no problem, we've already moved to an alternative supplier,'" David recalls. "The tone in that conversation completely changed. Suddenly they were asking what it would take to win our business back."

"I told them 'no problem, we've already moved to an alternative supplier,'" David recalls. "The tone in that conversation completely changed. Suddenly they were asking what it would take to win our business back."

Impermea had gone from captive customer to operating with leverage. The new supplier delivered in 4 weeks from initial contact. The original supplier? They came back with a proposal for shorter lead times and better pricing.

The operational shift

The operational shift

Impermea now operates with built-in redundancy. For every critical material, Tenkara maintains relationships with several qualified alternatives - pre-vetted, pre-quoted, ready to activate.

The cash flow multiplier

The cash flow multiplier

The credit terms agent delivered an unexpected win. While solving the packaging crisis, Tenkara identified that several of Impermea's raw material suppliers were willing to extend payment terms - they'd just never been asked properly.

Tenkara's agent automatically applied on David's behalf, using Impermea's strong business fundamentals and the fact that they were a growing account. Result: 60-day terms with four key suppliers, dramatically improving working capital during the facility scale-up.

"That cash flow cushion meant we could invest in equipment upgrades and inventory build without hitting the line of credit," David explains. "Tenkara gave us the financial flexibility to scale confidently."

"That cash flow cushion meant we could invest in equipment upgrades and inventory build without hitting the line of credit," David explains. "Tenkara gave us the financial flexibility to scale confidently."

Built for the next challenge

Built for the next challenge

Impermea is now expanding into new product lines and additional customer verticals.

Pre-Tenkara:

Each expansion would mean months of supplier development and relationship building.

After Tenkara:

Tenkara's agents are continuously mapping the supply chain for future needs. When Impermea decides to launch a new coating formulation, they already know which suppliers can provide the raw materials, at what lead tims to: alongside the cost and lead times.

"We're moving at chemistry speed now, not procurement speed," David says. "The speed we're moving at is insane, hard to fathom."

"We're moving at chemistry speed now, not procurement speed," David says. "The speed we're moving at is insane, hard to fathom."

Lead Time Recovery

8 weeks reduced to 4

8 weeks reduced to 4

Cash Flow Improvement

60-day payment terms unlocked

60-day payment terms unlocked

Facility Scale-Up

Boston to NC without supply chain disruption

Boston to NC without supply chain disruption

Ready to Ramp Up Your Operations?

Ready to Ramp Up Your Operations?

Optimize your manufacturing workflow

Optimize your manufacturing workflow

Optimize your manufacturing workflow

Optimize your manufacturing workflow

Optimize your manufacturing workflow

Optimize your manufacturing workflow