MANUFACTURING IMPROVEMENT MADE EASY BY VORNE

Real-Time Production Monitoring for Bottling

The bottling industry is characterized by repetitive, high-speed in-line or rotary filling lines in which manufacturers must precisely control external variables such as light, oxygen, temperature, and foreign contaminants in order to protect the integrity of their product. This creates a difficult challenge with respect to maintaining optimal line speeds, which is critical given that every extra fraction of a second adds up to significant losses over time.

The bottling industry services distributors, traders, wholesalers, and private labels, all of whom expect production to remain at the forefront of eco-friendly packaging and trendy label design. It’s no surprise that companies are seeking automated solutions, like Vorne XL, to monitor production and increase the visibility of the performance of their lines. Automated production monitoring can reduce operational costs and eliminate the inefficiencies and inaccuracies of manual data capture. Utilize 100+ metrics and 20+ data dimensions, including OEE, the Six Big Losses, TEEP, and more to dive deep into improvement opportunities.

Other benefits of XL that customers love include no software to install, no servers to maintain, no recurring fees, and no contracts. Instead, you get unlimited users, free technical support, a 3-year warranty, and free software updates. All in an inexpensive, off-the-shelf product.

Driving OEE Improvement and More in Bottling Manufacturing

Our bottling customers need to manufacture the products that their customers love with complete consistency while simultaneously striving to achieve greater efficiency and reduced environmental impact.

The Vorne XL Productivity Appliance empowers bottling manufacturers to monitor their processes in real time, improve throughput, and maximize efficiency, all while preserving the integrity of their products. XL drops onto your existing process, making it a quick and easy solution that requires little to no changes on the line. This is a unique and critical advantage of Vorne XL.

Screen capture of an andon report focused on a bottling facility taken from the Vorne XL OEE software.

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Key Benefits for Bottling Line Efficiency

Vorne XL is completely agnostic to the type of equipment in your manufacturing process. This is a huge advantage as you can easily apply XL to any process and get the same, consistent wealth of information. XL includes I/O to integrate with your process, a scoreboard for your operators, and built-in reporting for your managers. Even better, it scales easily and incrementally from machine to enterprise.

Real-Time OEE and Production Monitoring for Bottling

Whether you are bottling liquids, gels, powders, or capsules via manual, automated, or semi-automated in-line fillers, rotary fillers, gravity, pump, piston, overflow, or vacuum fillers, automate the process with one solution and quickly see benefits such as:

1
Changeover Times Instantly understand the impact bottle or label changes, sanitation, or CIP events have on your line’s availability. Even see minimum, average, and maximum times for each type. Plus, set changeover targets for your operators that automatically update in real time on the plant floor scoreboard.
2
Multiple Sensor Inputs Track production in terms of pieces, cases, barrels, vats, pallets, or even convert to volume or weight.
3
Real-Time Line Speeds in BPM/BPH Visualize line speeds and rates in real time and trend historical data by the product stream. Know right away when externalities contribute to small stops or running slowly.
4
Pareto Downtime by Machine or Asset Clearly and precisely understand your downtime and scan reasons to provide additional details. Tag when downtime is related to the filler, capper, labeler, case packer, accumulator, metal detector, etc. to target specific improvements on the line.
5
Modern Andon Visually see the status of each machine or process monitored by XL on a single page, providing instant direction to where your attention is needed most. Leverage automated alerts and notifications that escalate when appropriate.

You're In Excellent Company

Vorne XL customers span across 45+ countries and are in virtually every industry - including many in bottling. Take a look at a sampling of bottling manufacturers that have unlocked the benefits of XL to obtain accurate and actionable data, critical insights, and a foundation for their continuous improvement programs.

View a sampling of Vorne XL users in other industries

Learn More About Vorne XL

We would be happy to show you XL, deep dive into your challenges and your processes, and answer any questions you may have. We also offer free 90-day trials. In fact, we have completed thousands of successful XL trials. Did you know that 91.9% of companies that try XL buy XL?

Metrics, Dimensions, and Dashboards

Vorne XL provides you with an incredible data foundation and an outstanding suite of reporting tools to effectively drive your continuous improvement, lean manufacturing, and digital transformation initiatives. With XL you get immediate access to over 100 highly accurate and actionable metrics and 20 data dimensions - in real time and for deep retrospective analysis through historical reporting. There are dozens of built-in reports, and you can easily create your own reporting dashboards.

Screen capture of a dashboard created for a bottling manufacturer taken from Vorne XL.

Vorne XL User Success Stories

XL helps manufacturers in almost every industry improve their process productivity. You will love our free support, free software updates, 3-year warranty, transparent pricing, fast implementation, and of course, the wealth of product features. That is why we have so many customers that share their success stories.

F.S. Controls Engineer Fortune 500 Food ProducerVorne XL pays for itself in 2 days! Yesterday was the first time we looked at the results since installing XL. The direct result of the display was amazing. We went from running at $9,000 below target per month to a new gain of nearly $30,000 a month!

J.D. Maintenance Manager Food Products ManufacturerI have purchased and installed Vorne products for almost 10 years now, so I trust their ability to survive in a food manufacturing environment. The XL Series allowed me to introduce a new concept – real-time visualization – for very little cost and complexity. The alternative would have been to use PLCs, interface them with a PC, find and run software on the PC to drive the displays, and interface them with the displays. There is simply no comparison! I really like the product and will recommend it wholeheartedly to anyone.

W.M. Operations Manager Food Manufacturing PlantI've used Vorne XL in my last three roles and it has really made a difference. When I joined my last plant our OEE was 30%. Each month we picked a focus metric from the XL and trained the team on that metric. I showed everyone how it affected the line and then we worked together to drive up the number. We steadily improved, and when I left the plant our OEE was 74%!

G.K. Continuous Improvement Manager Global Food Service ProviderWe purchased a Vorne XL display to help us monitor production rates and apply lean manufacturing tools to one of our many value streams. By efficiently working to takt time, we have been able to eliminate waste and improve productivity, while maintaining our commitment to quality. We have calculated a 30 percent labor savings on our pilot project which yielded a 31 day payback. Since the pilot we have installed another two XL displays. As you can imagine, we will be continuing to add more Vorne displays!

D.G. Operations Manager Grain Milling and Packaging CompanyAfter we installed and deployed the Vorne XL Productivity Appliances we analyzed the data, and started understanding our underlying issues. We benchmarked our primary line and recorded an OEE Score of 45%. When we felt we had a good idea of what was going on, we started working to improve our productivity. We use OEE as the primary metric to gauge our progress. XL gave us the tools to track and eliminate our downtime, and improve our productivity. 10 weeks later we are hitting 60% OEE and still making improvements! Of our 10 best shifts of all time, 5 occurred in the last 30 days. Vorne XLs have been key to improving our productivity.

R.N. Continuous Improvement Manager Food Ingredients ManufacturerWe bought an XL system in September, and within a month we were seeing improvements of up to 8% in our OEE. Our OEE is now trending towards a 10% improvement. After our first month we visited Vorne for a 2 day training session and have left with a really solid plan to maximize how we use the system. We have now started introducing XL to our sister plants to align it with our group OEE methodology.

R.K. Maintenance Supervisor Decorative Can and Tin ManufacturerThe results are amazing! We went from about eight thousand units a day to just over eleven thousand just by putting the displays up. That's an almost 30 percent increase in production and we've been able to sustain our gains. Everybody in the plant just loves the displays. Supervisors, managers and operators now have a great tool for monitoring the progress of the lines in real-time.

T.G. Plant Manager Specialty Food Products ManufacturerWhen I saw XL I told our General Manager that this is the single most important investment we will make this year. Just the other day our CEO was walking through the plant. When he glanced at the production display, his jaw dropped. He was surprised to see over two hours of downtime. Without the display, it would likely be a whole lot more and we wouldn't find out until the next day when it is too late to fix it. XL really helps us put a spotlight on the dark areas and expose our productivity losses. XL is the secret ingredient for high efficiency!

M.H. Plant Manager Personal Care and Household ProductsAt Cosmetic Essence we have been aggressively working to improve our OEE and manufacturing efficiencies. So far this year, we have been able to achieve a 22% improvement in OEE, and Vorne XL has been an integral part of our improvement process. By knowing the status of all our lines in real-time, we can address problems in real-time. With XL, our entire team sees downtime, and eliminates downtime. We count on Vorne XL to show us what areas we need to address, and we take immediate action from there.

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We Support a Wide Range of Bottling Line Specialties

Our XL Productivity Appliance, with its fully integrated OEE reporting system, works well across an extremely broad range of bottling industry specialties. Here are some of the more common specialty areas where XL is used:

Beer Bottling
Beverage Bottling
Blow Molding
Bottle Filling
Can Seaming
Canning and Bottling
Carton Erecting and Sealing
Cooking Oil Production
Dairy Bottling
Energy Drink Bottling
Flexible Packaging Systems

Honey Production
Labeling and Printing
Palletizing and Depalletizing
Sealing and Capping
Shrink Sleeve Application
Spirits Bottling
Syrup Production
Tea and Coffee Production
Vinegar Production
Water Production
Wine Bottling

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What's included in your 90-day free trial?

VORNE XL | Works with any machine, any process, right out of the boxEasy, quick self-install | Accurate, real-time KPIs immediatelyTry XL for FREE today

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