Visualisation software brings bottling production line improvements to life

Conveyor and accumulation system specialist, Garvey by Columbus McKinnon (Garvey), wanted showcase the throughput and efficiency benefits of its bottle accumulation systems, which are suitable for a range of users from small breweries to large manufacturers of food, beverages, pharmaceuticals and household products.

An accumulation table is a specialised type of conveyor system designed to temporarily hold and accumulate products or materials. These tables can be circular, rectangular or even custom-shaped to fit specific production line requirements. They serve as a buffer zone in the production process, allowing for the smooth flow of items between different stages of manufacturing, filling, labelling or packaging.

Through relationships with its parent company, Columbus McKinnon, Garvey discovered digital twin visualisation software Emulate3D, by Rockwell Automation. Columbus McKinnon had previously engaged Australian company Glenvern Group, a Rockwell Partner, to visualise manufacturing projects and Garvey saw the potential of using Glenvern Group’s specialist Emulate3D application team to sell the benefits of its solutions globally.

“We could see that using 3D visualisation software that kept track of key data points and simulated real world conditions could better showcase the benefits of our accumulation systems,” said Bill Reese, senior director, engineering, Garvey.

Challenge

Garvey’s goal was to visually demonstrate how adding accumulation systems can reduce bottlenecks and improve throughput in a bottling production line.

“The challenge for us was finding a solution that could run on standard hardware and be easily manipulated during live demonstrations to potential customers. We didn’t have an internal solution, so Rockwell’s Emulate3D was ideal,” said Reese.

“It’s one thing to show a simulation that’s been created in advance, but being able to change inputs and show different scenarios in real time has been a game changer.”

Solution

Emulate3D provides a dynamic 3D modelling environment for creating high-fidelity physics-based models of discrete manufacturing and material handling systems.

“Glenvern Group has been specialising in Emulate3D (and its previous software versions) customisation and implementation for more than 20 years. It combines visualisation with simulation, virtual commissioning, and digital twin functionality,” said Alec Poulton, director, Glenvern Group.

“Having worked with other Columbus McKinnon companies across several different offices in the Asia-Pacific and North America, it was an exciting opportunity to work with Garvey in the US. We set up a full visualisation of a bottling plant that ideally showcased how accumulation systems can reduce bottlenecks and keep production flowing,” he said.

Garvey used Rockwell’s Emulate3D software and Glenvern Group’s expertise to accurately model its accumulation systems and display their benefits, backed by data, to potential customers. (Note: the simulation above shows the same bottling production line pictured earlier in the article.)

“Essentially, without an accumulation table, if one part of production stops, it all stops. With accumulation tables, you have an amount of buffer where production can continue in parts, while issues are fixed. It can also highlight optimum times for preventative maintenance, where it has the least impact on throughput,” he added.

The software is used globally by a range of industry sectors, including automation and materials handling, robotics, diverse manufacturing processes, logistics and warehousing, OEM and machine builders, airports and baggage handling.

Results

Through Emulate3D visualisation, Garvey was better able to demonstrate the benefits of its accumulation systems to key beverage customers.

“Screen-recorded demos, combined with live interaction, enabled our sales team to visually communicate critical production line insights, supporting customer acquisition efforts,” said Reese.

“The clear visual examples contained important data such as bottles packed, cases packed, including number packed per minute in the last 60 seconds and overall. We could use this data in a before and after demonstration to highlight the benefits of our accumulation systems.”

Columbus McKinnon now uses the software across multiple locations and companies, including Garvey and Dorner. In addition to supplying the software, Glenvern Group provided training, customisation, project guidance and ongoing technical support.

Conclusion

Garvey helps companies overcome complex production challenges, so having a clear, professional visual demonstration of how this is achieved — backed by data — is helping to grow sales efforts.

“Rockwell’s Emulate3D software is a game changer for us, and Glenvern Group is highly experienced in how to make the most of it. We’ve enjoyed the collaboration, and found Glenvern to be highly responsive with excellent communication throughout the project,” said Reese.