Digitizing performance for beverage bottling operations

Beverage and bottled water plants operate at high speed and scale, where limited visibility impacts performance, quality, and costs.

Altizon’s DFX Digital Factory turns bottling operations into connected, measurable systems, enabling teams to track losses, stabilize quality, and optimize energy and water usage across carbonated beverages and bottled water lines.

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Challenges in the beverages and bottled water industry

Quality and compliance pressure

Paper-based logs for product composition and quality checks create fragmented data that is difficult to reconcile. This lack of digital accessibility complicates audits and slows down batch recalls, creating a significant overhead for plant operations.

Hidden line losses

Frequent minor stops, set-up inefficiencies, and changeover losses across beverage lines dramatically reduce throughput and yield. Without digital visibility into these operations, high- speed assets remain underutilized, making it difficult to improve performance.

Utilities performance

High energy and water consumption from compressors, chillers, and CO2 systems create significant cost overhead. Without digital monitoring of these operations, inefficiencies remain hidden, making it difficult to control expenses and improve performance.

Fragmented operations

Paper logbooks and siloed legacy systems prevent real-time visibility into production health. Without digital integration, root-cause analysis is delayed and manual, making it impossible for operations to coordinate effectively and improve performance.

Altizon DFX: Unifying beverage operations with digital intelligence

Quality and compliance

Paperless in-process quality checks for raw material (RM) receiving, syrup preparation, carbonation, and filling operations
In-run checks: fill volume, torque, seal integrity, and label accuracy monitoring
Bill of Materials (BoM) validation during batch preparation
Digital checklists and traceability across batches
Statistical Process Control (SPC) and Process Capability Index (CpK) analytics for continuous improvement

Impact:

Line performance and OEE

Real-time OEE and loss analysis (Availability, Performance, Quality)
Automatic downtime capture, changeover, and CIP loss analysis
Floating bottleneck identification and V-curve speed optimisation
SKU-wise performance tracking and plan vs. actual production
Persona-based dashboards (Operator → CXO)
Multi-plant visibility and analytics

Impact:

Utilities optimization

Real-time monitoring of power, air, steam, and water
Track SEC, SWC, and energy per case to pinpoint utility waste
Equipment-wise energy benchmarking (blow moulder, compressor, chiller)
Early alerts for leaks, pressure drops, or idle consumption
Sustainability dashboards for water reuse, effluent, and waste

Impact:

Enterprise analytics

Integrates with ERP, Quality and other systems to unify data
Operations data lake for production, energy and quality
Cross-line and cross-plant analytics for benchmarking and centralised decision-making
AI/ML models for predictive downtime, process optimisation, and anomaly detection

Impact:

The Altizon advantage

Seamless data integration

Connect to any asset-from modern high-speed fillers to legacy compressors and chillers. Our platform bridges the gap between different generations of equipment to create a unified digital record of your operations.

Beverage-ready analytics

Skip the custom coding. We provide pre-configured templates for product composition, SEC, and SWC, allowing you to improve performance from day one with benchmarks specific to the bottling industry.

Error-proof digital forms

Move beyond simple digitizing. Our engine enforces validation rules on the floor, ensuring that quality data is accurate and reconciled in real-time to eliminate the overhead of manual audit preparation.

Global rollout capability

Our cloud-native architecture is built for the enterprise. Standardize your KPIs and operations across multiple geographies, providing the central visibility needed to improve performance at a corporate scale.

Proven improvements across bottling operations

3–5%

OEE improvements in High-speed lines

Identify root causes of micro-stops on critical fillers via digital monitoring to maximize throughput and improve performance.

10–15%

Productivity (Legacy lines)

Gain visibility into older operations to reduce downtime and boost output from existing assets without new capital expenditure.

15–20%

Lower quality deviations

Automate product composition checks to eliminate manual errors and ensure you are audit-ready without the ‘paper scramble.’

2-3%

Utility savings

Track SEC and SWC across compressors and chillers to pinpoint leaks and reduce the energy cost per case.

30%

Faster reconciliation

Digitize logs to accelerate batch recalls and root- cause analysis, removing significant administrative overhead from plant operations.

Altizon deployment roadmap

Pilot (6 weeks)

1 plant, 4 lines. quality and productivity digitization

Scale (10-12 weeks)

Scale up to the whole plant. Digitize energy and other utilities

Enterprise (20+ weeks)

Multi-plant rollout with centralized cockpit view

Case study snapshot

Pernod Ricard: Scaling operational intelligence across 30 facilities

Altizon’s Digital Factory Platform unified Pernod Ricard’s production, quality, and sustainability data by replacing fragmented,…

Varun Beverages: Standardizing performance across multi-OEM bottling lines

Altizon’s Digital Factory Platform helped Varun Beverages connect multi-OEM bottling lines and utilities into a…

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