Beverage Bottling Line Upgrade
Retrofit and modernisation of an existing bottling line with new automation controls and vision inspection.
62% → 84%
OEE Improvement
+10 years
Equipment Life Extension
-55%
Unplanned Downtime
30% saving
Project Cost vs Replacement
What the client needed
Replacing a 15-year-old bottling line outright was cost-prohibitive. The client needed a retrofit strategy that would modernise controls, add vision inspection, and deliver measurable OEE improvement — all without a full production shutdown.
How Smachinato delivered
Smachinato executed a phased retrofit replacing legacy relay logic with modern PLC controls, developing new HMI screens, and integrating an inline vision system for fill-level, cap and label inspection. OEE monitoring dashboards were added to give management real-time production visibility.
Scope of work
- Full PLC retrofit replacing legacy relay logic
- New HMI development with operator-friendly screens
- Inline vision inspection for fill, cap and label
- OEE monitoring dashboard with shift reporting
- Phased installation plan with zero full-line shutdown
Project Outcome
Extended equipment life by 10 years and improved OEE from 62% to 84%.
Project Details
Client
Regional Beverage Manufacturer
Industry
Beverages
Location
Maharashtra, India
Year
2022
Timeline
5 months (phased retrofit)
Technologies Used
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