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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.

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

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  1. Easier Than it Seems Canning quality product through innovation, design, and zip-ties. Jesse Brookstein

  2. 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.

  3. PHASE I • Interesting and intimidating transition. • Main difference: Where we needed to focus our attention. • Bottles - Filler, labels. • Cans - Filler, seams. • Whodathunkit?

  4. LINE 1 - SOLO

  5. 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.

  6. 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!!

  7. CIP BOX

  8. PHILLIPS BOX

  9. MOBILE STAIRS

  10. 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.

  11. 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.

  12. TUNNEL OF LOVE

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

  14. CONVEYOR CONNECTIONS

  15. COLLECTION TABLE

  16. DOUBLE TWIST RINSE

  17. PAKTECH CCA120

  18. DATE CODING

  19. EMPTY CAN FEED

  20. 6 PACK COLLECTION/PACK OFF

  21. 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.

  22. 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.*

  23. 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.

  24. TOP UP CONTROL

  25. END FEED

  26. PURE GENIUS

  27. 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.

  28. QUESTIONS?

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