Installation during production
Installation of the new bottling line began in mid-October 2024 but there was one challenge: The production hall where the line was to be erected was on the second floor, so the machines could not simply be rolled in. Instead, they had to enter the hall from above. The heavy line components were lifted over the roof of the hall and then precisely lowered into it – a logistical masterstroke. Each day, three to four machines were ingressed while production continued as usual.
“Installation during production was a definite challenge,” recalls André Marbach, the project manager. Each new machine that was erected shrank the space available. But safety at work and logistics pathways still had to be ensured at all times. “To protect the existing bottling line from dust and other interference factors, we erected a temporary wall for the flooring work,” says André Marbach. That enabled the team to perform work on the new line without affecting ongoing production – a measure, which not only ensured a clean environment but also made for a smooth transition.
By mid-December, all machines had been installed in their proper places. Next came intensive water tests, acceptance testing and validations – all of it aimed at creating the perfect production environment for FocusWater. Finally, the big day came in early March 2025: the successful start of 24-hour operation. All processes were already running smoothly by the second night shift. Martina Pfeiffer is full of praise: “That success would not have been possible without the dedicated work and enormous commitment of our entire workforce.”
From operator to optimisation specialist – thanks to digital transparency
It is not just the bottling line’s technology that’s new. Back in 2020, the Rivella Group joined forces with Krones to develop a Manufacturing Execution System (MES) based on SAP software, which is now also being used in the new bottling line and for the first time integrates the data from the Checkmat inspector as well – an additional quality-assurance feature that the old line did not have. This is instrumental in detecting any quality-relevant deviations even faster, thus significantly enhancing process reliability.
Both the new bottling line and digital transformation have changed the operators’ role: “Instead of changing over machines and controlling production processes manually, the operators are now supervising a highly automated line,” explains André Marbach. The automation software records malfunctions and performance data in real time and performs the requisite adjustments. That relieves the operators from routine tasks, so they can focus their attention on analysing and optimising production processes. “It’s quite exciting to watch that change. Thanks to the digital support we’re getting, we don’t have to intervene so often. We observe more closely, understand better and achieve more effectively targeted optimisation,” says Martina Pfeiffer.
With FocusWater rigged up for the future
The decision to buy and install the new bottling line resulted in a mammoth project, with a deliberate strategic alignment. That is because it has made sure that FocusWater not only enjoys optimum acceptance among consumers but also the best possible production processes. A modern, healthy beverage deserves an equally modern, smart environment for making it – and that is precisely what the new aseptic line is providing.
