Case Study: Carlsberg Brewery

Fastpack Business Engineering have completed an intensive turnkey project for Carlsberg’s brewery in Leeds, in less than 12 weeks.

The project is part of the £13 million investment in a new high speed canning line at the Joshua Tetley Brewery in Leeds. The line is a result of the continued can volume growth in the Take Home sector and will complement the 60,000 bottles per hour bottling line, which is currently being installed on-site. The can line will have the capacity to produce 90,000 cans per hour and production off the line is due in early 2006.

Involving the movement of two 50 metre long keg lines, the fast-track project included the supply of new conveyors, new electrical control system and major electrical installation works. Fastpack Business Engineering was selected to move the two keg lines 90 degrees to the side, to make room for two new high speed packaging lines.

The company was responsible for disconnecting, lifting, transporting and reinstalling the keg racker discharge equipment on each line. The existing cask-racking discharge equipment including the weigher, TrenStar keg tracking system and Unitiser was also relocated. 

Ian Forrester, Project Engineer for Carlsberg UK said: “Each line runs 24 hours a day and moves 1050 kegs every hour so we needed a partner that could complete the work very quickly, efficiently and safely. Fastpack BE presented a solution that met our needs exactly, making the best use of new and existing equipment to ensure minimal downtime and cost savings.”

Ron Morris, Project Manager at Fastpack BE comments: “This project involved very careful planning as the maximum downtime for each line was 10 days. To prepare, we supplied Carlsberg with a feasibility study and then based on this, worked in partnership with them to develop the most cost-effective solution and design layout.”

The solution also involved the supply of two conveying systems suitable for handling the complete range of containers including 36 gallon barrels.

The process and mechanical services were also modified and re-installed. Further works included modifications to the existing operator platforms and steps.