easier than it seems canning quality product through innovation, design, and zip-ties
DESCRIPTION
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, 2010 - We entered the world of canned craft beer. Four brands - Ellie’s, IPA, White Rascal, Joe’s. - PowerPoint PPT PresentationTRANSCRIPT
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EASIER THAN IT SEEMS
CANNING QUALITY PRODUCT THROUGH INNOVATION, DESIGN, AND ZIP-TIES.
JESSE BROOKSTEIN
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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.
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PHASE I
Interesting and intimidating transition.
Main difference: Where we needed to focus our attention.
Bottles - Filler, labels.Cans - Filler, seams.
Whodathunkit?
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LINE 1 - SOLO
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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.
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PHASE I
Initial Modifications
CO2 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!!
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CIP BOX
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PHILLIPS BOX
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MOBILE STAIRS
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PHASE II
Demand.
672 case day was a 14-16 hour shift.
Over 16,000 cans weighed individually.
Installed our 2nd line, conveyors.
Began relationship with Ball Corp.
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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.
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TUNNEL OF LOVE
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PHASE II
Modifications
Paktech CCA120.Conveyors linking lines together.Taptone low fill detection.Collection Table.Split twist-rinser.Permanent location for Domino.FNG’s.
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CONVEYOR CONNECTIONS
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COLLECTION TABLE
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DOUBLE TWIST RINSE
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PAKTECH CCA120
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DATE CODING
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EMPTY CAN FEED
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6 PACK COLLECTION/PACK OFF
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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.
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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.*
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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.
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TOP UP CONTROL
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END FEED
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PURE GENIUS
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MOVING FORWARD
3rd line?? 4th line??Rotary line??More brands in cans??
Quality of package and product.Differences between bottling and canning.Seam education and understanding.
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QUESTIONS?