Anheuser-Busch InBev (AB InBev) is one of the largest brewing groups globally, responsible for producing about one-third of the world’s beer. The conglomerate boasts a diverse portfolio of 630 brands and operates 260 breweries across the globe. With a significant presence in over 150 countries, AB InBev employs more than 170,000 people worldwide, including South Africa.
In South Africa, AB InBev operates seven breweries, one of which is the Pretoria South African Breweries (SAB) site, employing almost 900 people. At this plant, they mainly produce the popular South African beer brand, Castle Lite, and the well-known Mexican beer, Corona, with a combined production volume of approximately 8.5 million hectoliters annually.
To enhance the production capacity of Corona, AB InBev has incorporated a non-returnable glass line from Krones. The decision to choose Krones was influenced by the excellent relationship between the companies, compatibility with existing equipment, and high reliability standards, according to Theo Govender, the packaging manager.
This glass line is particularly notable for its exceptional speed, filling an impressive 100,000 glass bottles per hour. The line actually comprises two parallel lines, each capable of filling 50,000 bottles per hour, making it one of the fastest production lines in South Africa. This design not only ensures high output but also offers flexibility in simultaneously handling different beers, such as Corona and Castle Lite.
The line is designed to be extremely compact, featuring shared operating areas to enable operators to attend to multiple machines simultaneously, thus reducing the number of required operators, as explained by Boris Tremmel, head of Key Account Sales at Krones.
The line’s modular labeler, Ergomodul, allows for interchangeable labelling stations, facilitating quick switches to accommodate the beer currently in production. For Corona bottles, which have applied ceramic labels, the labeler is bypassed.
Regarding packaging, SAB has opted for two different packers on the line: the Variopac Pro WT for wrap-around cartons and trays, and the Variopac Pro PFS for shrink packs. Both packers are well-established for handling non-returnable containers. The Variopac Pro offers ease of change-overs and expansion, allowing packaging concepts to be adjusted as needed.
The line’s unique feature includes the use of the multi-functional clamping starwheel, MultiGuide Base, a first for AB InBev. This innovative component securely grips bottles with varying diameters without the need for manual intervention during format change-overs, eliminating production bottlenecks and enhancing efficiency.
