A leading household products manufacturer in the USA faced long and inconsistent bottle unscrambler changeovers, slowing their 24/7 production lines and straining operators. By replacing outdated change-part machines with POSIMAT’s POSIFLEX automatic changeover unscramblers, changeover time dropped from up to an hour to just one minute—while improving accuracy, ergonomics, and space efficiency.
Continue reading to see how POSIMAT transformed their bottling operations.
The customer is a multinational consumer health and hygiene company with a strong presence in the United States and one of the leading manufacturers of household products. Its most popular all-purpose cleaning products are packaged in a wide variety of HDPE and PET bottles.
Since 2000, the bottling lines at its New Jersey facility had relied on bottle unscramblers with change parts from another manufacturer, requiring between two and three sets of change parts per line. Given the plant’s 24/7 production schedule, efficiency is a critical factor.
Extended Changeover Time
Each format change required between 40 minutes and one hour, significantly impacting Overall Equipment Effectiveness (OEE).
Manual Changeovers
Format changes were carried out manually by non-specialized operators, leading to a lack of accuracy and repeatability, which further reduced OEE.
Ergonomic Challenges
The change parts were large and heavy, creating ergonomic issues and affecting operator well-being.
Space Constraints
Storing the bulky change parts occupied valuable factory floor space, limiting operational flexibility.
In 2000, POSIMAT installed the first POSIFLEX automatic changeover bottle unscrambler to replace one of the traditional change-part machines.
The success of this initial installation led to the gradual replacement of all change-part bottle unscramblers with POSIFLEX units between 2006 and 2008.
In 2024, a new production line was installed, also equipped with a POSIFLEX bottle unscrambler.
The results were immediate and transformative.
Dramatically Reduced Changeover Time
Changeover time was reduced to just one minute, significantly improving OEE.
Automated Precision
The automatic changeover process eliminated manual intervention, ensuring high accuracy and repeatability, which further enhanced OEE.
Improved Ergonomics
Eliminating change parts resolved ergonomic challenges and improved working conditions for operators.
Optimized Space Utilization
By eliminating the need to store change parts, valuable factory floor space was freed up for other uses.
POSIMAT’s POSIFLEX automatic changeover bottle unscramblers have revolutionized this company’s bottling lines, driving efficiency, accuracy, and operator satisfaction.
This success story demonstrates POSIMAT’s commitment to leveraging advanced technology and extensive expertise to deliver tangible improvements to the packaging industry.