FDBusiness.com

Increased Output and Reduced Costs in Soft Drinks Production

 Breaking News
  • HKScan Opens New €80 Million Poultry Plant HKScan, the Nordic meat group, has just opened its new, state-of-the-art poultry unit at Rauma in Finland. Valued at over €80 million, the new facility is the largest investment in HKScan’s history. Indeed, the state-of-the-art Rauma unit ranks among the most significant investments in the history of the Finnish food industry. Jari Latvanen, president and chief [...]...
  • Record Growth For UK Food and Drink Exports in First Half of 2017 The first half of 2017 saw exports of all UK food and drink grow to £10.2 billion, up 8.5% on the first half of 2016. This represents the highest first half exports value on record. The UK’s top 3 export products are whisky, salmon and beer. Contrary to recent export trends, stronger growth was reported [...]...
  • Nurturing Locally, Growing Globally – International Meat Congress ICoMST 2017 in Cork The 63rd International Congress of Meat Science and Technology (ICoMST 2017) took place at the Rochestown Park Hotel, Cork, during August 13-18, 2017 and was chaired by Teagasc’s Assistant Director of Research Declan Troy. Over 450 papers were presented at the congress, many by Teagasc researchers. The role of meat in strategies to achieve a sustainable diet [...]...
  • Tempting Batters Now With Clean-label Benefits A leading German natural starch producer, KRÖNER-STÄRKE, perhaps better known as a natural, starch supplier for bread manufacturers, has turned its attention to the convenience market. With a view to cleaning-up the unhealthy image of breaded or battered foodstuffs, the company has succeeded in developing specialist wheat starches which allow food processors to formulate on-trend, [...]...
  • B&R is Introducing a Hypervisor For Its Automation System B&R is introducing a hypervisor for its automation system. This software allows Windows or Linux to run alongside B&R’s own real-time operating system. That enables you to combine the control and HMI applications on a single PC, for example, or have an industrial PC double as both a real-time controller and an edge controller that [...]...
  • Florette Further Expands its UK Business In line with its strategy to be a major player within the UK fresh produce category, Florette UK & Ireland (part of the French Agrial group) has acquired the Wigan site of MyFresh Prepared Produce, a producer of a wide range of salad and vegetable products. MyFresh, Wigan, which employs almost 300 people and was [...]...

Increased Output and Reduced Costs in Soft Drinks Production

Increased Output and Reduced Costs in Soft Drinks Production
April 11
09:21 2014

An increase in machine reliability and the improvement of lubrication management practices in order to maximise output in one of their plants was the objective of a globally active soft drink producer when they approached tribology expert Klüber Lubrication. One of the plant’s seven bottling lines was chosen for the improvement project. Analysis was undertaken and this developed a comprehensive lubrication plan.  Following implementation mechanical breakdown was reduced, while output increased significantly.

Increased Production Output

The plant operates on a three-shift system, 24 hours a day. Theoretical filler speed of the bottling line is 24,000 bottles per hour. Prior to consulting Klüber Lubrication, utilisation was 55%: 1,760 cases were bottled per hour, equalling 42,240 cases a day. Klüber Lubrication went ahead with its proven KlüberEfficiencySupport package. Within nine months, production loss due to machine downtime was reduced from 7.4 per cent to 2.5 per cent, resulting in a substantial increase of production output: throughput increased to 72 per cent, equalling 2,304 cases per hour, or 55,296 cases a day – an increase by roughly 13,000 cases or 32 per cent a day. The increased production capability enabled rapid response to order and delivery schedules and a reduced unit cost of manufacture. In addition, the number of different lubricants was decreased from formerly 47 to 26, resulting in lower storage costs as well as a reduced risk of lubricant mix-up; all without compromising lubricant quality and standards.

Implementation in Practice

The comprehensive approach of KlüberEfficiencySupport includes the lubrication of all equipment throughout the entire bottling line. Klüber Lubrication proceeded in several steps. Based on a comprehensive pre-audit, the objectives to be achieved within a time frame of 12 months were fixed. The exact requirements of all persons involved in the lubrication process were precisely defined for the first time. In addition, intensive training sessions on lubrication matters took place. All this resulted in increased lubricant awareness and increased beverage safety.

A comprehensive lubrication plan and a food-grade lubrication regime for all lubrication points were implemented. Oil analyses were conducted as part of preventative maintenance programme.  In addition, storage conditions for the lubricants were improved. Klüber Lubrication also with an HACCP audit (Hazard Analysis and Critical Control Points) by implementing only ISO21469 manufacturing site H1 lubricants. Constant monitoring during the adjustment period ensured that all measures were fully implemented and, if need be, adjusted.

Conclusion

This case illustrates the significant influence lubrication has on the efficiency of machinery. Typical operating cost reductions for a food manufacturing plant can be more than £100,000 per annum. Implementation time for an advanced lubrication program is approximately six months, with payback in nine to twelve months. For many food processors it’s worthwhile to partner with Klüber Lubrication in order to analyse and adapt lubrication management practices to reduce costs and increase productivity.

About Author

mike

mike

Related Articles



Food & Drink Business Conference & Exhibition 2016

Upcoming Events

  • September 11, 2017drinktec
  • September 13, 2017FI Asia
  • September 19, 2017PROCESS EXPO 2017
  • September 22, 2017Global Summit on Food & Beverages
AEC v1.0.4

The Magazine

F&D Business Preferred Suppliers

Advertisements