In 2020, a customer was unable to reach the target output of its production line because two low-performance bottle unscramblers operating in parallel created recurring bottlenecks. Frequent stoppages reduced OEE to 65%, and even lower when one machine failed.
POSIMAT replaced both units with a single high-performance unscrambler capable of maintaining 265 bpm, allowing the filler and capper to run at full capacity and lifting OEE above 90%.
Continue reading to discover how the solution improved efficiency, freed up floor space and delivered a rapid return on investment.
CHALLENGE
In 2020, a customer faced ongoing production issues with their bottle unscrambling line. Their production line, designed for 250 bpm (bottles per minute), struggled to meet the target of 265 bpm due to bottlenecks caused by two low-performance unscramblers working in parallel. Frequent stoppages dragged the Overall Equipment Effectiveness (OEE) down to just 65%, sometimes even lower if one unscrambler failed.
SOLUTION
In June 2023, POSIMAT was invited to present a solution. By December 2023, we installed a single high-performance POSIMAT unscrambler, achieving consistent speeds of 265 bpm. This upgrade allowed the European filler and capper to operate at full capacity, raising OEE to over 90%.
CHALLENGES OVERCOME
• Budget Approval - Demonstrated a fast ROI by increasing OEE from 65% to 95%, securing investment approval.
• Space Constraints - Replacing two machines with one freed up floor space for raw material storage.
• Competition - POSIMAT’s track record and strong testimonials gave us the edge over other solutions.
• Accessibility Standards - The new unscrambler met the customer’s strict global standards.
• Recycled Plastic Bottles - Handled bottles with 30% recycled content, overcoming friction and handling
RESULTS
• Increased OEE by over 30% - now consistently exceeding 90%.
• Rapid ROI through higher efficiency and reduced downtime.
• Freed up valuable floor space.
• Customer is now standardizing POSIMAT unscramblers across global plants.
CONCLUSION
By replacing two unreliable machines with a single POSIMAT unscrambler, the customer unlocked the full potential of their production line. This success story proves how POSIMAT’s innovative solutions deliver measurable results and drive global standardization.