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Food & Beverage
2025
Bottling hall
Filling and capping line for a regional dairy
Filler, capper, labeller and case packer from four vendors, tied into one line controller with a single changeover button.
Client
Alder Creek Dairy
Duration
20 weeks
Scope
Line integration · Hygienic design · MES
24,000
bottles per hour
−62%
changeover time
99.7%
fill accuracy
The challenge
Four good machines that did not talk to each other. Every format change meant four operators at four panels and forty minutes of lost output.
What we built
A line controller that owns the recipe and pushes it to every machine, with accumulation tables tuned so one short stop no longer stops the line.
- Washdown-rated cabinets and stainless cable routes
- Line speed balanced around the filler as the bottleneck
- Batch records sent straight to the dairy's MES
Results
Changeovers dropped from forty minutes to fifteen, and the line now runs at its nameplate speed on every format.
Project data
Client
Alder Creek Dairy
Sector
Food & Beverage
Location
Bottling hall
Year
2025
Duration
20 weeks
More projects
Other lines we have commissioned.
Consumer Goods
2026
Panel forming line, rebuilt in eleven days
A 1990s relay-logic forming line moved to modern PLCs, remote I/O and a plant-wide SCADA view without losing a single production week.
+23 pts
OEE, 61% to 84%
11 days
planned shutdown
Automotive & EV
2026
Robot cell for battery tray handling
A six-axis robot now loads formed battery trays into the press line, guided by a camera that checks every part before it moves.
12.4 s
cycle time
2
operators moved to quality roles
Precision Machining
2025
Lights-out machining for aluminium housings
Two milling centres and a pallet store now run the night shift alone, with in-process gauging that corrects tool wear before parts drift.
3 shifts
with no operator at night
+41%
spindle utilisation
Next step
Planning something similar?
Send us a short description and a few photos of the line. A controls engineer will call you back.