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Coca-cola's New Canning Line
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INSIGHT: MANUEACTURING Coca-Cola's new canning line to raise capacity by 20M cases BY RICK PENOROUS Coca-Cola Enterprises' (CCE's) Sidcup factory in Kent will next month commission a new S14.3M line for the production of canned products. It will raise the plant's capacity by a further 20M cases a year. The new line, which will replace an existing squash line, has an extremely small footprint (just 1,500m'') and marks a continual programme of investment at the site, at which production started in 1961. While making the whole range of Coca-Cola and Schweppes soft drink brands, the site lays claim to being "the GB home of Powerade", according to operations director Steve Adams. Prior to the new line's start up, the site employed 370 staff working across seven production lines producing in excess of 42M cases of soft drink products a year. It has the largest range of packaging types of any CCE plant in the UK, including cans, plastic and glass bottles. Around 120 articulated vehicles pass through the site each day. The new turnkey line from KHS wiU initially produce 1.50ml and 330nü cans, vnth plans to introduce 500ml cans in future. It includes a depalletiser, filler, blender, tray shrink packer and single palletiser, which uses two Kuka robots for layer formation. It also has a GPI third generation tvwistack board multipacker. The line will feature several innovative features. These include a non-destructive online automatic X-ray seam inspection device from Sencon; online weight checks against the filler head; air - replacing water - rinsing of empty cans; and coding of cans prior to filling Other novel features include a vision system for empty can inspection to remove out of specification cans prior tofillingand seciming; and no can twists on the line, where cans are traditionally inverted to check for seaming failures or small micro leaks. Instead the new line will use an ultrasonic bath to excite the product to detect leaks. By removing the can tvnsts, changeover time is reduced. Also, the number of operator 'touch points' is reduced, which helps to reduce can dantage. The installation has involved major construction work to bring the area up to the latest CCE specifications, including fiooring, tilirtg, drainage and lighting. The materials warehouse will be increased from 1,300 pallet locations to 2,300 (20,0Q0m'^ to 25,000m'^). The site was recently certified an approved supplier to the Olympics next year by the London Organising Conmiittee of the Olympic and Paralympic Games. "To be here for 50 years, this site has had to improve year-on-year," said Adams at an event held at Sidcup site last month to celebrate the opening of CCE's fourth education centre there. "But improvement to us is not just about being more competitive year-on-year, it's about doing that in a sustainable way." Over the past year the site has achieved zero waste to lEindfill for the first time. It has reduced its water ratio (the number of litres used per litre of product made) to 1.67. It has also worked vdth various organisations to improve the local environment. Other targets set for the new line include a reduction of 610t of carbon dioxide by 2012, with 630t and then 700t set for subsequent years; water and energy reductions of 20% compared vnth existing canning lines; and a reduction in chiUing requirements due to ambient fiüng (21°C). Multimillion pound automation to extend bakery plant For the past two years, Cheshire-based family bakery Frank Roberts & Sons has been working on an automation project designed to ensure the plant baker continues to maximise its cost efficiency. Compliance engineers at Lorien Engineering Solutions, with which it has been working on the multimillion pound project, have now been engaged with the final stages of the development to extend the existing process and packaging plant, working with the bakery's international equipment suppliers. Tony Reynolds, compliance manager at Lorien, has been working with a bread slicing and bagging machinery supplier in Los Angeles and a basket conve5ing system engineering company in Christchurch, New Zealand. As well as assessing the machinery against European harmonised standards, Reynolds modified the guarding and control systems to Equipment must meet stringent safety legislation ensure that the equipment would meet the stringent CE marking legislation. Reynolds said: "Neither of the international suppliers had any practical experience of the Machinery Directive 2006/42/EC as required for CE marking, so Lorien stepped in to ensure that the machinery met with all the relevant EU legislation. By preparing the documentation for the CE technical file for Frank Roberts & Sons, we can ensure that employees are using safe and approved machinery." Frank Roberts produces around two million loaves, roUs and morning goods each week, which it supplies to the major multiples and independent stores across the country. 18 August 2011 FOOD manufacture www.foodmanufacture.co.uk
Transcript of Coca-cola's New Canning Line
INSIGHT: MANUEACTURING
Coca-Cola's new canning line toraise capacity by 20M casesBY RICK PENOROUSCoca-Cola Enterprises' (CCE's) Sidcup factoryin Kent will next month commission a newS14.3M line for the production of cannedproducts. It will raise the plant's capacity by afurther 20M cases a year.
The new line, which will replace an existingsquash line, has an extremely small footprint(just 1,500m'') and marks a continualprogramme of investment at the site, at whichproduction started in 1961. While making thewhole range of Coca-Cola and Schweppes softdrink brands, the site lays claim to being "theGB home of Powerade", according tooperations director Steve Adams.
Prior to the new line's start up, the siteemployed 370 staff working across sevenproduction lines producing in excess of 42Mcases of soft drink products a year. It has thelargest range of packaging types of any CCEplant in the UK, including cans, plastic andglass bottles. Around 120 articulated vehiclespass through the site each day.
The new turnkey line from KHS wiU initiallyproduce 1.50ml and 330nü cans, vnth plans tointroduce 500ml cans in future. It includes adepalletiser, filler, blender, tray shrink packerand single palletiser, which uses two Kukarobots for layer formation. It also has a GPIthird generation tvwistack board multipacker.
The line will feature several innovativefeatures. These include a non-destructiveonline automatic X-ray seam inspection devicefrom Sencon; online weight checks against thefiller head; air - replacing water - rinsing ofempty cans; and coding of cans prior to fillingOther novel features include a vision systemfor empty can inspection to remove out ofspecification cans prior to filling and seciming;and no can twists on the line, where cans aretraditionally inverted to check for seaming
failures or small micro leaks. Instead the newline will use an ultrasonic bath to excite theproduct to detect leaks. By removing the cantvnsts, changeover time is reduced. Also, thenumber of operator 'touch points' is reduced,which helps to reduce can dantage.
The installation has involved majorconstruction work to bring the area up to thelatest CCE specifications, including fiooring,tilirtg, drainage and lighting. The materialswarehouse will be increased from 1,300 palletlocations to 2,300 (20,0Q0m'̂ to 25,000m'̂ ).
The site was recently certified an approvedsupplier to the Olympics next year by theLondon Organising Conmiittee of the Olympicand Paralympic Games.
"To be here for 50 years, this site has had toimprove year-on-year," said Adams at an event
held at Sidcup site last month to celebrate theopening of CCE's fourth education centrethere. "But improvement to us is not just aboutbeing more competitive year-on-year, it's aboutdoing that in a sustainable way."
Over the past year the site has achieved zerowaste to lEindfill for the first time. It hasreduced its water ratio (the number of litresused per litre of product made) to 1.67. It hasalso worked vdth various organisations toimprove the local environment.
Other targets set for the new line include areduction of 610t of carbon dioxide by 2012,with 630t and then 700t set for subsequentyears; water and energy reductions of 20%compared vnth existing canning lines; and areduction in chiUing requirements due toambient fiüng (21°C).
Multimillion pound automation to extend bakery plantFor the past two years, Cheshire-based familybakery Frank Roberts & Sons has beenworking on an automation project designed toensure the plant baker continues to maximiseits cost efficiency.
Compliance engineers at Lorien EngineeringSolutions, with which it has been working onthe multimillion pound project, have now beenengaged with the final stages of thedevelopment to extend the existing processand packaging plant, working with the bakery'sinternational equipment suppliers.
Tony Reynolds, compliance manager atLorien, has been working with a bread slicingand bagging machinery supplier in Los Angelesand a basket conve5ing system engineering
company in Christchurch, New Zealand. Aswell as assessing the machinery againstEuropean harmonised standards, Reynoldsmodified the guarding and control systems to
Equipment must meet stringent safety legislation
ensure that the equipment would meet thestringent CE marking legislation.
Reynolds said: "Neither of the internationalsuppliers had any practical experience of theMachinery Directive 2006/42/EC as requiredfor CE marking, so Lorien stepped in to ensurethat the machinery met with all the relevantEU legislation. By preparing thedocumentation for the CE technical file forFrank Roberts & Sons, we can ensure thatemployees are using safe and approvedmachinery."
Frank Roberts produces around two millionloaves, roUs and morning goods each week,which it supplies to the major multiples andindependent stores across the country.
18 August 2011 FOOD manufacture www.foodmanufacture.co.uk
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