A project for the general soft drinks co ltd (gsd) of malta, the country’s sole licensed bottler of coca-cola products, has demonstrated the capacity to add new technology to an existing line with min
20 August 2015
20/08/2015
The decision to acquire the new Rollquattro labellingmachine from Sidel the world's leading global provider of PETsolutions for liquid packaging was taken after GSD had consideredthe retrofitting of an existing rollfedlabeller.
"With the high season about to start, we consulted Sidel -originally to have our existing Rollquattro rollfed labellerretrofitted with all the relevant upgrades," commented Brian Galea,Technical Manager at GSD. "Sidel undertook a carefulevaluation of the whole situation on our behalf. When theypresented the results of this thorough analysis and the comparableimprovements we would likely be faced with by investing in the newmachine, we quickly saw the value and sense of the option that theywere suggesting, particularly when we realised the potential forinstalling it in such a short timeframe" he continued.
Staying competitive in a cost-driven market
Within the local bottled water market Malta effectively competeswith neighbouring Italy, a country with an annual bottled water percapita consumption of 176 litres. Water volume sales for thewhole of Italy - one of the largest producers of bottled water inthe world - totalled 11 billion litres in 2014 according to reportsby market analyst Euromonitor. Italians and Maltese generally treatmineral water as an everyday drink, rather than a luxuryitem. However, the number of competing brands inevitablyresults in a fiercely tough marketplace where the price is drivenlow and great profitability is difficult to achieve. GSD isconsequently run on measurable performance indicators that areregularly monitored to ensure every aspect of production is keptcompetitive and profitable. This naturally includes theperformance of any labelling equipment involved in the process.
Consulting with Sidel to improve TCO
GSD first started working with Sidel in 2002 whenit purchased its first Sidel line to produce water in both glassand PET bottles. In 2007 a second line was added, this timedevoted to only the PET bottling of carbonated soft drinks in a newmodern plant and the old line relocated. Both the original lineswere moved and subsequently updated with a line conversion in2012. Then, when the company decided to improve theefficiency and total cost of ownership (TCO) of the older lineoriginally supplied 12 years earlier, the company naturally againturned to Sidel. The flexible line - used to produce still,sparkling and flavoured water in 0.5, 1.0 and 2.0 litre bottles inboth glass and PET - is equipped with standalone equipment. This includes a single blow moulding machine with different fillersand labellers for each packaging material.
Set up to make installation fast and simple
The original PET labelling machine that had given seven years ofsuch efficient and reliable service on the line was a SidelRollquattro labeller. Following the evaluation of the options,this was replaced by the new labeller to provide even furtherbenefits. Just like the previous machine, the new Rollquattrofrom Sidel is for the application of rollfed labels. GSDs'new labeller has the same overall dimensions as the old machine,with a potential output rate of up to 25,000 bottles per hour, andmakes use of the same changeover parts. This in itselfcontributes to the reduction of the overall cost of theGSD investment.
The machine is fully tested by Sidel technicians before shippingto ensure it is simple to install in place of an existing machine,keeping stoppage time to an absolute minimum and reducing theimpact on production. For GSD, the whole process, fromdismantling the old labeller to the production of the firstsellable bottles on the new Rollquattro, took only five days. "Withthe new machine fitted within a matter of days - and CustomerAcceptance Validation reached in under three weeks as we hadrequested - we were able to tackle production for our high seasonwith even greater labelling efficiency. At the same time, wehave optimised the TCO of labelling PET bottles on the line"commented Brian Galea.
Efficient and highly precise
Qualitative plastic labels areapplied on all the different waters and formats by the newRollquattro, supporting the market positioning of the brand Kristalwater. The label transfer drum, glue and cutting modules ofthe new machine are designed to deliver high accuracy and qualitytime after time. The patented label transfer drum ensureshigh quality labels fit to bottles. The automated vacuum,with easy and programmable settings, increases label tension andstability control. The label application and overlapalignment are precise at every speed, even for shaped bottles, withno additional wipe-down system required for label overlapclosure. Each of the four integrated single rotating cuttingblades is highly durable and designed for up to 5,000 workinghours. The glue roller's knurled pattern design leads tosignificant savings in glue and the roller unit ensures theadhesive remains in excellent condition and, with accuracy andsimplicity, always achieves optimal application.
Flexible labelling solution and lowmaintenance
Brian Galea continues: "GSD production is changed roughly threetimes every day. So production flexibility in terms of changeoverof materials, formats and labels, is essential to us. With acompact footprint, the new Rollquattro linear station design makesaccess to machine modules easy, thereby making changeovers informat faster. With adjustments for both bottle and labelconfigurations made via the human machine interface (HMI), we nowfind that we can carry out changeovers within only thirtyminutes."
The ergonomic linear design of the new Rollquattro providescontrol of all labelling processes and allows for simplermaintenance procedures. Modules can be removed from thestation and worked on separately. Reduced wearing between theglue-vacuum-drum-cutter roller and the lack of lubricationdecreases the need for maintenance. The glue tank, locatedunder the machine base, can be easily and safely accessed by theoperator and the vacuum prevents labels from entering the glueroller area to reduce the need for cleaning.
About General Soft Drinks
GSD produces and bottles an extensive range of soft drinks fordistribution throughout the whole of Malta and neighbouring Gozo.GSD is owned by the holding company of the Mizzi Organisation, aconglomerate with a portfolio of business units covering variousdifferent industries. The company employs over 225 people atits manufacturing plant, offices and its distribution centre on theisland. As an independent bottler, GSD is the sole licensedbottler of products for The Coca-Cola Company on the island.
