leeds factory tour - britvic/media/files/b/britvic-v3/documents/pdf/... · filling and packing •...
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From empty bottle to pallet in 25 minutes Leeds factory tour
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Welcome to our factory This booklet provides an overview of the processes and equipment you will see on the factory floor.
You will find an overview of our tour on the back page. Look out for numbered signs as you walk round, as each one corresponds to a different stage in the production process, and has a relevant page in this booklet.
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The production process
Pasteurisation
Carbonation
Rinsing, filling and capping
MultipackingPalletising and shipping
Packaging
Mixing and blendingIngredients
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Mixing the drinks
Filling and packing
Quality inspection and coding
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Labelling
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Mixing the drinks• Inourmixingroomwater,sugarandsyrupsarecarefully measuredandmixedtogetherinhugestainlesssteeltanks.
• Weproducebothstillandcarbonated(sparkling)drinksandwe havetomixmanydifferentrecipes.
• Aftermixing,sparklingdrinksarecarbonatedbydissolving carbondioxideintotheliquidathighpressure,whichtransforms theirflavourandmouthfeel.
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Did you know?
Our production lines are up to 350 metres long to prevent bottles from building up and delaying the process if there is a short stoppage.
Traffic light
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Filling and packing• Theproductionareaiswhereallthepartsofthefinishedproduct arebroughttogether.Precisionandaccuracyarevitaltothe operationrunningsmoothly.
• Weoperatetwoshiftsperday,eachwith24people,andour techniciansareonhandincasetheproductionlinefails.Atraffic lightsystemisusedtoindicatehowthemachinesareworking: ifyouseearedlightthemachinehasstoppedandtheoperator mayrequiretheassistanceofatechnician.
• Ourthreeproductionlinescanoperateroundtheclock,upto120 hoursperweek;wedonotworkonSaturdaynightsorSundays.
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Packaging• Weusetwodifferentkindsofpackaging.
• Line4producesbaginboxsyrups,usedbybars,pubsand restaurantswhichhaveourbrandsontap.Foilbagsarefilledunder pressure,thenpackedintoboxes,whicharestampedwithabest- beforedate,anddetailsofwhenandwheretheywereproduced, beforebeingshrink-wrappedinpolythenefilmandpackedon pallets,readyfordespatch.Wecanfillupto13bagsaminute.
• Lines1and3producearangeofbottledreadydrinks,juicesand mixers,whicharealsosoldthroughpubsandotheron-premise outlets.
• Allourglassbottlesandcardboardpacksaremadefromrecycled materials,andweworkhardtominimisethevolumeofwastewe sendtolandfill.
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Did you know?
Our line 3 filler runs at around 600 bottles a minute, producing around 30,000 cases of product a day.
Pasteuriser
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Rinsing, filling and capping• Emptybottlesaredeliveredinbulk,unpackedandputontothe productionlinewhichtransportsthemtotherinser,wheretheyare inverted,clampedintopositionandrinsedwithpurifiedwater beforebeingturnedbackuptherightwayandtakentothefiller.
• Thebottlesarefilledasthefillingmachinerotates,sothateachone isfilledtothecorrectlevelatexactlythemomentitiscappedand carriedoffonaconveyorbelt.
• Bottlescontainingjuicebaseddrinksthenspenduptoanhourin thepasteuriser,wheretheyareheatedtoatemperatureofapprox 86degreescentigradeandthencooledinordertodestroyany naturallyoccurringbacteriaormould.
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Did you know?
The labeller has a maximum speed of 39,000 bottles per hour, and can label a range of different sized bottles.
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Labelling• Onleavingthepasteuriser,bottlespassthroughanairdryerto removeanymoisturedropletsbeforebeingconveyedtothelabeller.
• Itappliespre-printedlabelswithspecialgluetofixthelabel securely,eveninchilled,wetconditions.
• Labellingoffoodanddrinkproductsishighlyregulatedandall Britvicproductsarelabelledincompliancewithlegislationand supplementarycodesofpractice.Weincludetheproductnameand description,ingredients,nutritioninformationpanelandguideline dailyamounts.
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Quality inspection and coding• Oncefilled,allbottlespassthroughanelectricsensor,toensure theyarefilledtotherightlevelandthatthecaphasbeenfitted correctly.
• Samplesfromeverybatchofproductwemakearetestedinour lab,withourexpertscarefullyexaminingthetaste,appearance, sugarandpHlevelstoensureallourdrinksconformtoBritvic’s highqualitystandardsandregulations.
• Weretaineverysampleforreference,enablingustodoublecheck forshelflifeandidentifyanyproblemsthatmayoccur.
• Afterlabelling,eachbottleisprintedwithabest-beforedateand detailsofitsdate,timeandlineofmanufacture.
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Did you know?
The tunnel is heated to a temperature of approx 170 degrees centigrade.
Film
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Multi-packing• Thebottlesarecoveredlooselywithfilmbeforepassingthrougha heattunnel,wheretheyareheatedtoatemperatureofapprox 170degreescentigradefor10seconds.Theheatcausestheplastic toweldtogetherandshrinktightlyaroundtheproduct,givingthe packitsstrengthandrigidity.
• Ourline1and3packerscanbeadjustedtoaccommodatearange ofdifferentcaseformats.
• Allourcardboardpackagingismadeentirelyfromrecycled materialsormaterialderivedfromsustainablesources.Aspartof ourongoingefforttosaveenergyandreducepackaging,weare workingtoremovethecardboardtraysfromourshrinkwrapped packswhereverpossible.
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Did you know?
Our factory can produce over a million cases of soft drinks per month.
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Palletising and shipping• Thepalletiserisprogrammedtoconfigurethecasessothatthe maximumnumbercanbeloadedontoeachpallet.
• Fullpalletsarestretch-wrappedtoensuretheyarestablefor transport.Thefilmwrapispre-stretchedbyatleast200%sothat lesscanbeusedandwhatisusedwillnotstretchanymoreon thepallet.• Onanaveragedaywesendout25lorryloadseachconsistingof 24fullpallets.
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LINE 1
LINE 4
LINE 3
PRODUCTION HALL
WAREHOUSE
CLOAKROOM/TOILETSRECEPTION
SYRUP ROOM
LINE 4
PROCESS YARD
BUFFER TANK(WATER MAINS)
WATERTREATMENT
PROCESS
COLD STORE
RAW MATERIALS
POWDER ROOM
CIP
OFFICES
ENG. STORESWORKSHOPBOILERSWATER TANKCO2
WATERTREATMENT
CARPARK
STORAGE YARD
WAREHOUSE
HARDSTANDING
LOADING BAYS
DISTRIBUTION YARD
LEARNING CENTRE
MAIN ENTRANCE
PAS
TEU
RIS
ER
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3
4
567
8
3
Mixing the drinks
Filling and packing
Packaging
Rinsing, filling and capping
Labelling
Quality inspection and coding
Multi-packing
Palletising and shipping
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2
3
4
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Ifyouwanttolearnmore,checkouttheBritvicLearningZoneonlineatwww.britviclearningzone.com