The challenge
World-renowned Scotch whisky and gin producer Chivas Brothers needed a partner to help boost production efficiency at their new-look Kilmalid bottling site in Dumbarton. Key to achieving this would be the seamless integration of a new third-party pallet handling system into their existing setup. With competition in the drinks sector so high, the required upgrades would also need to be implemented within a fast-tracked timeframe to keep downtime and disruption to a minimum.
The Automatica solution
After assessing the requirements for handling high-speed, tapered bottles within a compact space, our experts selected the Lita Metro bottle de-palletiser for the task. This sophisticated system would allow operators to load pallets of glass onto the in-feed conveyor with a forklift, input the glass type and pallet code via the HMI (human machine interface) and finally automate the de-palletising process.
As with all Automatica projects, identifying any opportunity to increase sustainability was front of mind. In this case, the system selected for the upgrade featured a pneumatic robotic arm that efficiently removed layer trays, which could then be sorted ready for recycling.
In line with the client’s expectations, bottles were able to be transferred at speeds of up to 250 per minute to the bottling line, with manual adjustments made for premium glass bottles.
The fully automated setup also ensured empty pallets were stacked and removed efficiently, maintaining a high throughput at all times.
“The upgrade was fast-tracked to commence production within three months to minimise downtime. Extensive pre-delivery testing and trials were made in Turin by Automatica, alongside the Chivas Brothers project team, to ensure a seamless installation at the Kilmalid facility.”
The result
Following the system upgrades, Chivas Brothers saw a significant increase in operational performance and reduction in costly bottle breakages, essential when dealing with a product that’s often been patiently aging for 25 years before ever reaching the conveyor. This commitment to speeding up automation without compromising standards has also further strengthened the brand’s reputation as pioneers in premium Scotch whisky and gin production.
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