Carlsberg uses multiple smart sensors across their global bottling sites to pinpoint breakage issues and improve overall efficiency.
A line was experiencing high levels of highly-visible breakage and the noise of the glass-on-glass contact was extremely loud. Carlsberg needed to eliminate the breakage and its related downtime to reach target output efficiency.
Operations staff tried various methods to identify what was going wrong but nothing worked. They lacked the data they needed to find a solution.
“Where glass breakage occurs is not necessary the highest or the only high-impact area,” notes Carlsberg Senior Packaging Expert Jane Tinning.
ShockQC™ (in an acrylic replica of the client's bottle) was placed on the Carlsberg line and the real-time data from multiple runs identified the problem areas. Breakage was happening near the packer, but the largest impact area was occurring in the de-packer at the beginning of the filling line.
Use of ShockQC™ determined that impacts received by bottles were causing damage on the bottle surface and weakening the glass until other impacts further down the line (though small) caused breakage.
"Our Packaging Field Expert Team travels from Carlsberg brewery to Carlsberg brewery on a continuing basis, and uses Masitek products extensively during the analysis part of the visit and then at the end once all the identified issues have been fixed,” Tinning explains. “The moment we make an adjustment, we can see immediately if we have fixed the issue.”