Intelligent control thanks to MES: KHS optimizes production processes at the Mark Anthony Group
A project of superlatives: the Mark Anthony Group completed its new production site in Glendale, Arizona in just 280 days.
- Beverage group invests in four canning lines and one repackaging line for variety packs from KHS at its Glendale site
- Successful automation of the packaging processes thanks to Innoline MES
- Software system enables automatic media supply and disposal of the lines and relieves the workload on technical personnel
Dortmund, 13 September 2022 – A project of superlatives: the Mark Anthony Group completed its new production site in Glendale, Arizona in just 280 days. The greenfield project is among the largest and most modern breweries in the USA. With four canning lines and one repackaging line for variety packs, the KHS Group is making a major contribution to the success of this ambitious undertaking. The beverage giant benefits from the reliable execution of production orders and impressive system efficiency thanks to the Innoline MES (Manufacturing Execution System) production control system from the full-service provider from Dortmund. The smart digital system supports the processes of the company group for the automatic media supply and disposal of the system. This relieves the workload on operating staff considerably.
The Mark Anthony Group and its subsidiary Mark Anthony Brewing have been racing from one growth record to another since 2016 - made possible by the spectacular success of their White Claw brand of hard seltzer. The group claims a market share of around 50% in the United States with its trend drink in the ready-to-drink segment. The beverage manufacturer worked exclusively with contract bottlers during the first few years to produce its hard seltzer. Only the alcoholic segment was brewed and filtered by the company itself. In the boom year of 2019, however, the Mark Anthony Group decided to produce its trend drink only in-house. In order to autonomously satisfy the tremendous demand, the company built three new locations in the USA within 30 months, including one in Glendale, Arizona.
Automation optimizes production processes
When it comes to filling and packaging technology for its 93,000-square meter site, Mark Anthony Brewing relies on the expertise from KHS. The turnkey supplier is contributing four high-performance canning lines. The heart of the systems is the high-performance Innofill Can DVD filler including a Ferrum seamer. The bottler is also investing in an Innopas WICG compact heater, an Innopack TSP tray shrink packer and various Innopal PB NF and AS N palletizers.
The new repackaging system from KHS for variety packs is of central importance for production as the main product White Claw is sold primarily in popular cartons containing up to six different flavors. Previously, the beverage cans had to be transported to another location after filling where they were repackaged mainly by hand – a time-consuming and costly process involving the risk of container damage. Thanks to the new line designed for the production of mixed packs, the cans from the filling lines can be immediately packed into variety packs. As an integrated IT system, the Manufacturing Execution System (MES) aids the customer in planning and executing the relevant orders for the system.
KHS masters complex tasks
After filling, the beverage cans travel to the packaging systems where they are combined to form either variety packs or monopacks. There is also the option of placing the containers on what are known as work-in-progress pallets and storing them temporarily there. The Innoline MES from KHS, which communicates automatically via interfaces with Mark Anthony Group’s ERP system1, supports the complicated distribution process, as Wolfgang Heßelmann, the responsible product manager at KHS, explains: "The MES manages approximately 80 different production scenarios or routes through the lines. It helps to continuously distribute the cans to the various packaging systems according to the current on-hand stock and demand.” This not only increases the flexibility, but also boosts the efficiency of the system significantly.
The KHS production control system also plays a decisive role in implementing complex material supply processes by communicating with the self-propelled conveying systems used for palletizing and in Mark Anthony's warehouse and generating transport orders. "What are known as LGVs2 notify our MES, for example, if there is still a sufficient quantity in stock for a requested material. If not, a replacement material is automatically requested,” explains Heßelmann. This automatically prevents production downtimes.
Workload relieved at all levels
What's more, the KHS productive system substantially reduces the workload on trained personnel. "Operators are able to directly request material and view the status of LGV missions using an MES webpage embedded in the control panel of the system," Heßelmann points out. It also automatically records all goods movements and forwards the data to the ERP system. This enables the trained personnel to view in real time the current production entries as well as consumption and production figures for all pertinent goods such as empty cans, filled containers, cartons, etc. “Thanks to the automatic inventory check, the staff never loses track of the material flows. This is a great advantage - especially for companies like the Mark Anthony Group that have a wide range of products but only limited amount of storage space,” Heßelmann explains.
The Basic Line Monitoring system from KHS integrated into MES provides additional security. The web-based system captures all significant system data that can be accessed at any time via the HMI control panel. In addition, this smart system offers options for fault and long-term analyses. "The Mark Anthony Group is excellently prepared for the future thanks to our software systems," says Heßelmann. "As a result of the outstanding cooperation with the customer’s team, we were able to complete this complex task from the initial planning phase to final acceptance in less than twelve months. We have demonstrated that we are a reliable partner in the field of IT for our customers as well.”
1 ERP-System = Enterprise-Resource-Planning-System
2 LGV = Laser Guided Vehicle
Canning line
Mark Anthony Brewing Inc. has invested in four canning lines and two repackaging lines from KHS for variety packs at its Glendale site.
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Packaging system
The new repackaging system from KHS for variety packs is of central importance for production as the main product White Claw is sold primarily in popular cartons containing up to six different flavors.
Download image (JPG, 119 KB)
Palletizer
Among other things, the bottler has invested in various Innopal PB NF and AS N palletizers.
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Laser guided vehicles
Laser guided vehicles notify the KHS production control system if there is still a sufficient quantity in stock for a requested material, for example. If not, a replacement material is automatically requested.
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Innoline MES
The Innoline MES from KHS, which automatically communicates via interfaces with the Mark Anthony Group system, provides support for complex distribution processes.
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Wolfgang Heßelmann
"The MES manages approximately 80 different production scenarios or routes through the lines. It helps to continuously distribute the cans to the various packaging lines according to the current on-hand stock and demand," says Wolfgang Heßelmann, product manager for the Innoline MES at KHS.
Download image (JPG, 72 KB)