Big step on the way to reducing greenhouse gas emissions: After KHS installed a state-of-the-art PET single-use line at Schweppes Zimbabwe Limited (SZL), the bottler not only produces much more efficiently, but also uses resources more sparingly – while simultaneously increasing capacity by 300 percent compared to the previous line.
Until recently, Schweppes Zimbabwe Limited’s production in the Willowvale industrial estate in the capital Harare was still designed for small quantities. But this has changed with the recent installation and commissioning of a completely new PET disposable line. The beverage producer is now convinced that it is well equipped thanks to the latest KHS technology – including a compact InnoPET BloFill stretch blow molding and filling block for producing and filling up to 36,000 containers per hour, the efficient Innoket Neo labeling machine for roll-fed labeling of the bottles, the Innopack PSP Advanced shrink packer and the flexible Innopal PB N palletizer. Continuous monitoring of the KHS inspection technology ensures that only containers of perfect quality leave the factory. There are several reasons why the decision was made in favor of the Dortmund-based full-service provider, as Ropafadzo Gwanetsa, Corporate Affairs Executive at Schweppes Zimbabwe Limited, emphasizes: “KHS is considered a proven system supplier to our parent company Coca-Cola and is valued for its know-how in the field of highly efficient filling and packaging systems. The holistic service with comprehensive technical support is also convincing.”
Production capacity increased by 300 percent
Schweppes Zimbabwe Limited is particularly impressed by the speed of the plant: According to Gwanetsa, production capacity has increased by 300 percent compared to a competitor’s previous line – so much so that the existing warehouse will probably have to be expanded. A necessary step, as demand for bottled juices from the flagship brands Mazoe Orange Crush or Minute Maid, Bonaqua Still Water and Schweppes Still Water continues to rise, both in the domestic and regional markets.
The professionalization of production is also evident in the flexible processing of various packaging sizes from 400 milliliters to 2 liters. “The ability to process a wide variety of container sizes on one line without complications, for example with regard to quick format changes, is a major market advantage for us compared to other bottlers,” explains Gwanetsa, who also appreciates the automated processes of the new acquisition. “Intervention in the line by operators could be reduced to a minimum, which has improved the efficiency of our production.”
Gwanetsa uses further figures to illustrate the positive development resulting from the modernization: “Compared to the previous solution, we were able to reduce overall costs by around 80 percent. A reduction in personnel requirements of 10 percent makes a positive contribution to this.” In terms of resource conservation, the new KHS system also scores points with up to 30 percent lower energy consumption, savings in water and CO2, and lower labeling costs at a comparable level. “Together with the entire group, we are pursuing an ambitious sustainability strategy with an immediately noticeable reduction in greenhouse gas emissions and the goal of climate neutrality. The state-of-the-art KHS technology is helping us to successfully pursue this path.”
Less use of plastic through lightweighting
Savings in the area of resources are also reflected in the lower use of materials for primary packaging. Thanks to the tried-and-tested KHS stretch blow molding technology, high-quality PET lightweight containers are now produced using up to 15 percent less raw materials. Gwanetsa also mentions another important criterion in terms of sustainability: the longevity of the machines. “We are planning the new PET disposable line for the next 20 years,” says the Schweppes expert. The longer a bottler operates a system, the smaller its ecological footprint over its entire life cycle. “Our machines are often used successfully by customers for several decades and this alone ensures less pollution of the environment,” confirms Bradley Naicker, KHS Sales Manager South Africa, who reports on a particular challenge in this project: Since the spatial conditions at Schweppes’ production site in Hahare are very cramped and the new system had to be installed in a small area, the KHS experts adapted the line to the available space. It was installed in an L-shape rather than the usual rectangular shape – and in record time. Thanks to the excellent cooperation between the project team from KHS and Schweppes Zimbabwe Limited, the first saleable product rolled off the production line just six weeks after commissioning.
Individual implementation of customer requirements in the area of palletizing
Special customer requirements were also taken into account in the area of robot-controlled palletizing. Due to the production of PET bottles in special formats, the bottler uses special pallets which, like the containers, do not conform to the standard. “We were able to adapt the palletizer to the respective SKUs by individually programming the robot and thus deliver an optimal result,” explains Naicker. Ultimately, the successful project management by the system provider contributed to Schweppes’ complete satisfaction. “As part of the holistic KHS service offering, we benefited greatly from the close support throughout the entire period. This was evident from the training courses carried out and the holistic knowledge transfer from KHS technicians to our local team. After commissioning, we will continue to receive remote training,” says Gwanetsa. “The processing times are short and the technicians are always available.” The KHS ReDiS (Remote Diagnostic Service) has proven to be a valuable system and has significantly supported the knowledge transfer process and the maintenance of the system after commissioning.
Naicker also looks back with pleasure on what has been achieved: “We have exceeded expectations in terms of production capacity, profitability and resource consumption. Schweppes Zimbabwe Limited now bottles more drinks at lower costs, with better quality and with a smaller carbon footprint .”
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