He Does $6M a Year Bottling Water. One Robot Almost Broke Him.
Jay Peterson got out of Boston College in 1991 into no jobs, went home to Kankakee, Illinois, and sold industrial real estate for a broker who gave him the listing nobody wanted: a hundred acres next to a dynamite plant. Two years later some friends set him up as a Canteen distributor with one route truck and two vending machines. He and his wife Myra were the first two employees. They canceled their honeymoon to take on a Sears distribution center. That vending company got to about $10 million. He sold it in 2001, kept the water and coffee routes, sold those in 2005, and then a fax came across his desk. Nestle Waters had bought every independent water company in the country to compete with Coke and Pepsi, figured out they only wanted the dense markets, and was selling off the rest. Jay bought the Evansville, Indiana routes, with a Toyota plant and an Alcoa can plant on the customer list, for $225,000 on $1.1 million of revenue. That's Mountain Glacier. He's run it for 20 years. Today it's a $6 million co-packing plant putting out about 2 million five-gallon bottles a year. 40 truckloads a week, with a plant that can do 80. He went from 30,000 home-delivery customers down to 15 big ones. The sales are there. What's in the way is a robot. He bought it at a trade show, waited two years for it to be built in Poland, and got it dropped on his floor last June with a two-week install in the contract. It took seven months. The suction cups couldn't hold 20% of his bottles. The layout meant he couldn't go back to hand loading without cutting his throughput in half. He ran the plant around the clock from June to October, put about a million dollars of his own money in, and his father-in-law named the robot Philip Bottles. This year Philip is the employee of the month, every month. The hole from last year is still there. We break down: Why vending machines aren't the passive income YouTube says they are: you need a million dollars of revenue before you can afford a money room and a warehouse, and until then the husband fills machines at night and the wife does the books Route density, and why Nestle wanted a truck parked in front of a Manhattan tower all day but not Buffalo What's actually in the bottle: spring water at 200+ TDS, remineralized RO at 50 to 100, distilled at 3 or less, and how he blends a recipe to whatever a customer specs Where I pushed back on the robot. It always takes longer than they say, and you don't tear out the way you get product out the door until the new way is proven The freight company that came with the water business: 12 day cabs, 30 trailers, and a $700,000 SBA note, six months into unwinding it one truck at a time Why I told him to rip the Band-Aid off. I did it over 12 to 18 months and I should have done it in one auction. Trucks don't get more valuable, the insurance doesn't get cheaper, and the problem eats your attention the whole time Why he should not sign the three-to-five year freight contract J.B. Hunt is about to offer him. A rate per lane, a fuel surcharge, revisited every year. Anything more complicated than that and you're getting screwed somewhere Three SBA 7A notes, everything collateralized, and what a bad robot year does to your covenants Whether $600,000 or $2 million actually fixes anything, and why "capital constrained" is usually shorthand for something else The assignment I gave his son Jake, who just joined with an accounting background: a 13-week cash flow model, every dollar in and out, closed within a week of month end, done in 60 days, and nothing else on his desk until it is The line I kept coming back to: if you're upside down on half the business, doubling it might just make you upside down by double. Jay wants to go from 40 loads to 80. I don't know if that's a good idea, and neither does he, because nobody has the numbers yet. Once they do, the next move will be obvious to him, to his bank, and to anybody he'd ask for money. Until then everybody is guessing. Jay is 57. He's spent 33 years horse trading in and out of businesses, and what he wants now is one the Peterson family keeps for another 20. The water is fine. The plant is fine. Culligan wants it. What he has to get right is the boring part.
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