Beverage manufacturer: Simulation identifies bottlenecks in bottling and palletising
Software: Plant Simulation
A beverage manufacturer wanted to examine its bottling and packaging lines, as well as its palletising process, in greater detail. This was because production bottlenecks were jeopardising supplier planning, and a suitable control system was still required for a colour-sorting hopper.
Initial situation: Bottlenecks jeopardise supplier planning
The manufacturer wanted to safeguard its supplier planning by identifying and eliminating production bottlenecks. In addition, SimPlan was tasked with developing a control system for a colour-sorting storage unit, as no solution was yet available for this.
Objective: Focus on filling, packaging and palletising
The simulation was intended to answer the following questions:
- How do the filling and packaging lines, as well as the palletising process, interact?
- Where are the existing bottlenecks and what measures can eliminate them?
- How can order sequencing and the product mix be optimised?
Solution: Plant simulation using a custom-developed library
SimPlan modelled the plant using the Plant Simulation software in versions 10.1 to 13.0. As there were no suitable modules available for filling plants, SimPlan developed its own library for this purpose. SimPlan also utilised the LogisticSuite for the pallet conveyor system. To ensure that the input data did not have to be entered manually, SimPlan also set up an automatic interface.
Plant simulation using the Plant Simulation software
- Custom-developed library for the simulation of filling plants
- Use of SimSuite for pallet conveyor systems
- Automatic interface for input data
Results: Bottlenecks eliminated, palletising capacity increased
The simulation revealed where the bottling lines were becoming blocked, enabling the manufacturer to eliminate these bottlenecks. Furthermore, palletising capacity increased because SimPlan restructured the pallet conveyor system, optimising both the control logic and the order mix in the process.
Note: No specific figures, such as percentages or quantities, are available for the raw materials; therefore, the results section has been deliberately kept general at this point.
Why bottleneck simulation matters for beverage manufacturers
Filling and packaging lines are closely linked to upstream and downstream processes such as palletising and warehousing. Consequently, a single bottleneck can quickly affect the entire line. Simulation makes such interdependencies visible before any changes are made to the actual system. This applies not only to the beverage industry, but to any production facility with similarly synchronised lines.