Page 58 - Packaging New magazine Jan-Feb 2023

MACHINERY MATTERS JANUARY – FEBRUARY 2023 ■ 14
CASE STUDY
CCEP opens new canning line in Moorabbin
Coca-Cola Europacific Partners has pressed go on the most advanced canning line in its network in the Australasian region, a project that was two years in the making and delivered in partnership with key technology suppliers including KHS, GPI and Matthews Australasia.
Packaging International (GPI), including a QuickFlex TwinStack G3 machines for fully enclosed multipacks of between six and 30 cans and a Marksman for straight or gusset wrap around multipacks of four and six.
The KHS Innopack Kisters packer enables loose or prepacked product to be processed via an energy-saving shrink tunnel using tray and shrink or shrink only, rounding out the new lines ability to cater for all of CCEP’s current packing offerings.
KHS also supplied a high- speed, low-level robotic palletising system, integrating Kuka robots.
End-to-end traceability
Holden said another key supplier integrally involved in the project was Matthews Australasia, who played a significant role in delivering level of technology and systems capability to meet the high speed and flexibility requirements.
Matthews regional sales manager Matt Nichol confirmed Matthews provided a completely integrated solution using iDSnet to integrate to CCEP’s ERP (SAP) system using work orders to start a run and integrate all coding, labelling and barcode scanning technology across all formats of the production line
– primary, secondary and palletising.
“iDSnet simplifies the start of run process catering to the multiple packaging formats CCEP is running on the high-speed production line,” Nichol said.
For primary coding, Matthews supplied a 100w Fiber laser (the SolarJet FL10) capable of printing at speeds of 2000 cans per minute. For secondary coding, Matthews installed several Linx 8900 series inkjet coders printing traceability codes onto the shipping packs. Matthews also integrated barcode scanners inside these packaging machines to ensure the correct packaging material is loaded, eliminating any potential packaging errors.
A range of CCEP pack formations require TUN labels to be applied for scanning through
The new line, built at the cost of close on $44m and housed at CCEP’s production site in Moorabbin, will allow the beverage manufacturer to scale its local can production significantly, and increase the flexibility around the packaging configurations it delivers to customers across Victoria, Tasmania and South Australia.
CCEP project lead David Holden said he is excited to see this cutting-edge line up and running, after a two-year timeline, and said delivering this project required “tremendous teamwork and collaboration” with partners to overcome the constraints placed on them during Covid.
“The new Moorabbin line is a significant capability shift to provide a diverse range of products for customers across
Victoria and interstate. It introduces leading technology available on the market, capable of packing over 37 different varieties of product, at a highly efficient rate over 24/7 operations to meet the demands of our customers,” Holden said.
Automating for flexibility
CCEP fills and pack cans into a range of pack formations, multipacks, cluster packs and slabs, across 37 different beverage varieties, including Coca-Cola No Sugar, Sprite, Mount Franklin Lightly Sparkling, Canadian Club & Dry, Monster, and Mother Energy.
Beverage packaging specialist KHS was tasked with leading the line integration project in collaboration with the CCEP team. It also supplied the majority
of the equipment on the line. KHS Australia managing
director Jens Kautzky said, “The KHS team handled the full execution and commissioning of the line using only local resources for project management and service support.”
Kautzky added: “This is the most automated canning line of its kind in the southern hemisphere in terms of its ability for fast changeover. With other lines like this, manual adjustment is required when changing between packaging formats, on this line it is fully automated.”
Processing capacity of the KHS Innofill Can DVD line is 1200 cans per minute for 500ml, 1500 cans per minute for 375ml and 1700 cans per minute for slimline 250ml cans. The line can handle a variety of formats and sizes, from mini 250ml cans to 375ml and 500ml packs. Cans are supplied by Orora Beverage.
Commenting on the sustainability attributes of the filling line, Kautzky described it as “truly world class”, not only because of its speed, but because it can fill at ambient temperature while still achieving the high speeds typically associated with cooler filling temperatures, saving energy and CO2 in the process, in line with efficient mixing system supplied by KHS.
Holden said that while the line is operational, validations are still underway with various brand partners. Once it is fully operational, he confirmed that it will have the capacity to provide an additional 11 million cases of product to the Victorian market.
Flexibility and agility is delivered not only through the KHS canning line but also the automated secondary packing systems supplied by Graphic
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ABOVE & LEFT: Poetry in motion: CCEP's most advanced canning and secondary packaging line in action.