Solutions by industry / Food & beverage
Stable blow moulding, 98% good bottles
A leading American bottling company used Wizata to stabilise preform heating, catch process deviations early and predict bottle quality in real time, across 16 plants.
The challenge
Consistent bottle quality across 16 plants
The company runs 16 manufacturing plants and a portfolio of more than 438 brands. On its blow-moulding lines, variations in heating parameters and process deviations were causing quality to fluctuate from one shift to the next.
Every fluctuation cost money further down the line:
What the team set out to do
- Refine the production parameters of the blow-moulding process.
- Improve quality assurance on every line.
- Give engineers predictive tools for real-time decisions.
- Find the root cause of deviations instead of reacting to them.
Our approach
Three models along the blow moulder
Wizata and the customer's team deployed one integrated solution, running on the same digital twin of each line.
Set-point recommendations
A real-time optimisation engine suggests adjustments to the critical heating parameters, keeping the process stable and consistent.
Anomaly detection
Continuous monitoring flags process deviations before they turn into quality issues or machine stoppages.
Quality prediction
Machine-learning models forecast the quality outcome and reveal the variables that influence it most, so improvements are targeted.
Blow moulder monitoring in the Wizata Control Panel: rejection reasons, blowing pressures, preform and oven temperatures, live alerts.
The outcome
Better bottles, fewer disruptions
Bottle production quality, with a measurable and rapid return on investment.
Production efficiency
Smoother production, fewer disruptions and more stable parameters.
Higher yield
More high-quality bottles, with less waste and rework.
Data-driven decisions
Engineers and operators adjust faster and more accurately, which also improves maintenance planning.
Built on the Wizata platform
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Bring the same stability to your lines
You don't have to do it alone. Talk to one of our engineers, or spend one or two days with our team on your own data.