Easier Than it Seems Canning quality product through innovation, design, and zip-ties

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.

PHASE I

Interesting and intimidating transition.

Main difference: Where we needed to focus our attention.

Bottles - Filler, labels.Cans - Filler, seams.

Whodathunkit?

LINE 1 - SOLO

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.

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!!

CIP BOX

PHILLIPS BOX

MOBILE STAIRS

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.

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.

TUNNEL OF LOVE

PHASE II

Modifications

Paktech CCA120.Conveyors linking lines together.Taptone low fill detection.Collection Table.Split twist-rinser.Permanent location for Domino.FNG’s.

CONVEYOR CONNECTIONS

COLLECTION TABLE

DOUBLE TWIST RINSE

PAKTECH CCA120

DATE CODING

EMPTY CAN FEED

6 PACK COLLECTION/PACK OFF

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.

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.*

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.

TOP UP CONTROL

END FEED

PURE GENIUS

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.

QUESTIONS?