Use Case
Beverage Industry
AI-Driven Blow Molding Optimization

Challenge

A leading bottling company operating 16 manufacturing plants and managing a diverse portfolio of over 438 brands, faced persistent challenges in maintaining consistent quality in blow-molding bottle production. Variations in heating parameters and process deviations were creating fluctuations in quality, leading to increased waste, operational downtime and higher production costs.

The company aimed to refine its production parameters, improve quality assurance, and implement predictive tools capable of supporting real-time decision-making and root-cause analysis.

Approach

Wizata collaborated with the customer to deploy an integrated AI-driven solution designed to stabilize production conditions and enhance quality performance across their plants.

Set-points recommendations

A real-time optimization engine suggesting adjustments tocritical heating parameters, ensuring stable and consistent blow-molding operations. 

Anomaly Detection System

An intelligent monitoring tool identifying process deviations before they escalate into quality issues and machine stoppage. 

Predictive Classification Tool

Machine learning models forecasting quality outcomes and uncovering the most influential variables in production, enabling targeted process improvements. 

Outcome

The implementation brought measurable improvements across critical aspects of the producer's operations:

Production Efficiency

More streamlines production, fewer disruptions and improved parameter stability. 

Increased Yield

Significant improvement in the production of high-quality bottles reducing waste and rework. 

Data-Driven Decision

Automated insights empowered engineers and operators to make faster and more accurate adjustments, improving long-term process reliability and maintenance planning. 

Quality Improvement - ROI

Bottle production quality increased from 94% to 98%, providing a measurable and rapid return on investment.