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Varun Beverages: Standardizing performance across multi-OEM bottling lines

Altizon’s Digital Factory Platform helps Varun Beverages transform multi-OEM bottling lines and utilities into a single digital layer, replacing isolated systems with real-time visibility into OEE, energy consumption, and utilities performance across plants.

Altizon’s impact

8–10%

OEE improvement

6–8%

reduction in energy consumption

4

plants digitized

16

bottling lines digitized

The challenge: Untracked micro-stoppages and inconsistent performance reporting

Lack of real-time data across multi-vendor lines and utilities prevented a unified performance baseline. This prevented correlation of micro-stoppages with output losses, causing sub-optimal production.

Fragmented production visibility
Isolated OEM systems: Proprietary monitoring tools were siloed to individual machines, preventing an integrated view of the bottling line.
No end-to-end line view: Lack of data correlation across blow molders, fillers, and labelers blocked the identification of systemic bottlenecks.
Reactive downtime analysis: Manual logs and shift-end reports delayed loss detection, forcing reactive rather than proactive intervention.
Invisible energy consumption
Hidden utility cost: Energy consumption for compressors, chillers, and boilers was trapped in paper logs, lacking granularity and masking peak-load inefficiencies.
Delayed loss identification: Consumption spikes and efficiency drifts were only detected post-factum, leading to unrecovered utility waste.
No production correlation: Inability to link utility draw to specific line states or batch volumes prevented an accurate “energy per unit” cost baseline.
Inconsistent operational governance
Expanding blind spots: Rapid multi-site growth magnified the lack of a central digital layer, making uniform performance oversight impossible.
Fragmented operational standards: Without a unified platform, disparate plant-level reporting prevented the enforcement of enterprise-wide best practices.
Subjective operational response: Without real-time data, shift teams relied on “gut-feel” and localized workarounds rather than data-driven root cause analysis.

As operations scaled, Varun Beverages needed a vendor-neutral digital layer that could connect multi-OEM bottling lines and utilities into a single, real-time view across plants.

The solution: A unified digital operations platform

Altizon partnered with Varun Beverages to build a vendor-neutral Digital Factory layer that connects multi-OEM bottling lines and utilities into a single, real-time system—without disrupting ongoing operations.

Production performance
  • Multi-OEM lines were connected to a single digital platform to measure throughput.
  • Real-time line dashboards showed output, speed losses, and stoppages.
  • Automatic fault mapping and hourly summaries highlighted exact downtime reasons.
  • Shift teams could act immediately to clear bottlenecks and stabilize line speeds.
Outcome:
  • Operators and supervisors gain live visibility into losses and performance.
  • 8–10% improvement in OEE across high-speed bottling lines.
  • Connected meters captured real-time energy usage across bottling lines and utility areas.
  • Dashboards visualized consumption by line, shift, and process.
  • Alerts flagged sudden spikes and gradual drifts before they escalated.
  • Teams traced issues to root causes such as overloaded compressors or inefficient run sequences.
Outcome:
  • 6–8% reduction in overall energy consumption driven by real-time awareness and faster intervention across bottling lines and utilities.
  • Live dashboards tracked pressure, flow, temperature, and energy usage for compressors and chillers.
  • Early warning signals surfaced issues before breakdowns occurred.
  • Operations and maintenance teams balanced loads, improved uptime, and reduced energy waste.
Outcome:
  • Improved utility reliability, reduced energy waste, and more stable plant operations.

How Varun Beverages experienced measurable and sustainable gains

Before Altizon
After Altizon
Outcome
Productivity and OEE
Manual data capture with delayed downtime analysis
Real-time OEE dashboards with automated loss visibility
8–10% improvement in OEE across bottling lines
Energy consumption
Manual meter readings with limited insight into losses
Continuous monitoring with alerts and trend analysis
6–8% reduction in overall energy usage
Utilities performance
No live visibility into compressors and chillers
Real-time monitoring of pressure, flow, and energy
Improved reliability and reduced energy waste

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Standardize performance across your global bottling network.

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