EASIER THAN IT SEEMS CANNING QUALITY PRODUCT THROUGH

  • Slides: 28
Download presentation
EASIER THAN IT SEEMS CANNING QUALITY PRODUCT THROUGH INNOVATION, DESIGN, AND ZIP-TIES. JESSE BROOKSTEIN

EASIER THAN IT SEEMS CANNING QUALITY PRODUCT THROUGH INNOVATION, DESIGN, AND ZIP-TIES. JESSE BROOKSTEIN

 Avery Brewing Company opened in 1993. Bottling and kegging for 17 years. August,

Avery Brewing Company opened in 1993. Bottling and kegging for 17 years. August, 2010 - We entered the world of canned craft beer. Four brands - Ellie’s, IPA, White Rascal, Joe’s.

PHASE I Interesting and intimidating transition. Main difference: Where we needed to focus our

PHASE I Interesting and intimidating transition. Main difference: Where we needed to focus our attention. Bottles - Filler, labels. Cans - Filler, seams. Whodathunkit?

LINE 1 - SOLO

LINE 1 - SOLO

PHASE I Realities 24 CPM (105 BPM) DO - 60 -80 ppb. * CIP

PHASE I Realities 24 CPM (105 BPM) DO - 60 -80 ppb. * CIP - No mechanical action on fill stems. * No pallet control. * Date coding difficulties. * No automated low fill detection. 336 case day - 8, 000 cans weighed individually. Seam saw - no seam stripper.

PHASE I Initial Modifications CO 2 knife - Post filler. Stainless CIP box -

PHASE I Initial Modifications CO 2 knife - Post filler. Stainless CIP box - PBR cans = bad idea. Pallet box. Mic stand(s) for date coding. Metal surface on can feed platform - CAN JAM!!

CIP BOX

CIP BOX

PHILLIPS BOX

PHILLIPS BOX

MOBILE STAIRS

MOBILE STAIRS

PHASE II Demand. 672 case day was a 14 -16 hour shift. Over 16,

PHASE II Demand. 672 case day was a 14 -16 hour shift. Over 16, 000 cans weighed individually. Installed our 2 nd line, conveyors. Began relationship with Ball Corp.

PHASE II Realities 48 CPM (105 BPM) Applying Paktechs by hand. * Efficient three

PHASE II Realities 48 CPM (105 BPM) Applying Paktechs by hand. * Efficient three man work area. 672 shift required a four man shift (7 -5). Seam saw - no seam stripper. Ball Corp. location and cooperation -Don Muntz.

TUNNEL OF LOVE

TUNNEL OF LOVE

PHASE II Modifications Paktech CCA 120. Conveyors linking lines together. Taptone low fill detection.

PHASE II Modifications Paktech CCA 120. Conveyors linking lines together. Taptone low fill detection. Collection Table. Split twist-rinser. Permanent location for Domino. FNG’s.

CONVEYOR CONNECTIONS

CONVEYOR CONNECTIONS

COLLECTION TABLE

COLLECTION TABLE

DOUBLE TWIST RINSE

DOUBLE TWIST RINSE

PAKTECH CCA 120

PAKTECH CCA 120

DATE CODING

DATE CODING

EMPTY CAN FEED

EMPTY CAN FEED

6 PACK COLLECTION/PACK OFF

6 PACK COLLECTION/PACK OFF

PHASE III Demand – Customers/employees love cans. 672 cases: 10 hr shift. 1344 cases:

PHASE III Demand – Customers/employees love cans. 672 cases: 10 hr shift. 1344 cases: 16 -18 hr shift. Rumors of 30 CPM per line. Seam education. Focusing on the details.

PHASE III Realities PLC modifications – Avg. 30 CPM per line. 672 case day

PHASE III Realities PLC modifications – Avg. 30 CPM per line. 672 case day – 8 hr shift (7 -3). Fluctuating fill volumes. * 4 man shift due to seam inspections (stripper). * Greater beer/can loss due to line speed. *

PHASE III Recent/Planned Modifications PLC modifications - Individual fill head control. PLC modifications –

PHASE III Recent/Planned Modifications PLC modifications - Individual fill head control. PLC modifications – Foamer valves (? ? ) Seam analysis on production floor. Increased conveyor speed – Paktech/date code. Preventing can/end/product loss. Team adjusting to machine speed/learning curve. Increased PM. Learning from every error.

TOP UP CONTROL

TOP UP CONTROL

END FEED

END FEED

PURE GENIUS

PURE GENIUS

MOVING FORWARD 3 rd line? ? 4 th line? ? Rotary line? ? More

MOVING FORWARD 3 rd line? ? 4 th line? ? Rotary line? ? More brands in cans? ? Quality of package and product. Differences between bottling and canning. Seam education and understanding.

QUESTIONS?

QUESTIONS?