From empty can to pallet in 25 minutes Rugby factory tour

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Welcome to our factory Our Rugby factory is the biggest production site within the Britvic group, producing up to half of all our drinks. This is also the only Britvic factory that makes drinks in cans and these equate to about 75% of total production, the rest is made up by plastic bottles (PET).

The factory is also home to Britvic’s only aseptic production line – this is a special type of production that enables us to make drinks that are free from preservatives but without the need for refrigeration.

This booklet provides an overview of the processes and equipment you will see on the factory floor.

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The production processMixing the drinks

Filling and packing

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Ingredients Mixing and blending

Pasteurisation

Carbonation

Packaging

Rinsing, filling and sealing

Palletising and shipping

Labelling

Multipacking

Quality inspection and coding

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Did you know?

We do not use artificial colour or flavours in any of our drinks.

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Mixing the drinks• Inourmixingroomwater,sugarandsyrupsarecarefullymeasured andmixedtogetherinhugestainlesssteeltanks.

• Weproducebothstillandcarbonated(sparkling)drinksandwehave tomixmanyrecipes.

• Aftermixing,sparklingdrinksarecarbonatedbydissolvingcarbon dioxideintotheliquidathighpressure,whichtransformstheir flavourandmouthfeel.

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Did you know?

We fill cans at a rate of up to 90,000 per hour.

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Filling and packing• Theproductionareaiswhereallthepartsofthefinishedproduct arebroughttogether.Precisionandaccuracyarevitaltothe operationrunningsmoothly.

• AtRugbywehaveapproximately250employees,andoursix productionlinesoperate24/7.

• Ourtechniciansarealwaysonhandincaseanyproblemsarise.A trafficlightsystemisusedtoindicatehowthemachinesarerunning: ifyouseearedlightthemachinehasstoppedandtheoperatormay requiretheassistanceofatechnician.

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Did you know?

We buy 12,825 tonnes of metal cans per year, weighing as much as 2.5 x Blackpool Tower.

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Packaging• AtRugbyweusebothcansandPETpackaging.

• Lines1,5and6producePETbottlesandlines2,3and4 producecans.

• Cansaremanufacturedanddelivereddirectlytoourproductionlines fromthefactorynextdoor,andweblowmouldallourPETbottlesin ourfactory,significantlyreducingtheenvironmentalandfinancial costsoftransport.

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Labelling• Labellingoffoodanddrinkproductsishighlyregulatedandall Britvicproductsarelabelledincompliancewithlegislationand supplementarycodesofpractice.Weincludetheproductnameand description,ingredients,nutritioninformationpanelandguideline dailyamounts.

• Althoughwelabelsomebottlesaspartofourownproductionprocess, allourcansarriveatourfactorypre-printedbyourmanufacturers.

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Did you know?

We use 2,500,000 litres of water a week – enough to fill an Olympic swimming pool.

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Rinsing, filling and sealing• Cansareproducedatthefactorynextdoor,eliminatingtheneed fortransportation.Theyaredelivereddirectfromthesuppliertothe productionlineonaconveyorsystemviaanundergroundtunnel.

• Oncethecanshavebeenrinsedandfilled,theeasy-opentopis quicklyfittedwithaseamer,whichturnsthelipofthetopoverthe sidesofthecantoprovideanairtightseal.

• Thecaniswarmedtodryoffmoistureandeliminatecondensation inordertopreventrust.

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Did you know?

We do over 5,000 quality checks every day.

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Quality inspection and coding• Oncefilled,allcanspassthroughanelectricsensor,toensurethey arefilledtotherightlevelandthatthetophasbeenfittedcorrectly.

• Samplesfromeverybatchofproductwemakearetestedinour lab,withourexpertscarefullyexaminingthetaste,appearance, sugarandpHlevelstoensureallourdrinksconformtoBritvic’s highqualitystandardsandregulations.

• Weretaineverysampleforreference,enablingustodoublecheck forshelflifeandidentifyanyproblemsthatmayoccur.

• Afterfilling,eachcanisprintedwithabest-beforedateand detailsofitsdate,timeandlineofmanufacture. 6

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Did you know?

If we lined up all the cans we produced last year they would lap around the world four times.

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Multi-packing• Ourmulti-packersonlines2,3,4and5canhandleallofour differentpackformats.

• Allourcardboardpackagingismadeentirelyfromrecycled materialsormaterialderivedfromsustainablesources.Aspart ofourongoingefforttosaveenergyandreducepackaging,weare workingtoremovethecardboardtraysfromourshrinkwrapped packswhereverpossible.

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Palletising and shipping• Thepalletiserisprogrammedtoconfigurethecasessothatthe maximumnumbercanbeloadedontoeachpallet.

• Ourcanpalletsarestabilisedusingthe‘LockandPop’or gluingmethod.• Onanaveragedaywesendout70lorryloadseachconsistingof 24fullpallets.

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100%

Ifyouwanttolearnmore,checkouttheBritvicLearningZoneonlineatwww.britviclearningzone.com

WAREHOUSE (FULL GOODS)HIGH-LEVEL CONVEYORS

LINE-5

LINE-3

LINE-4

LINE-1

LINE-2 SYRUPROOM

FULL PALLET CONVEYOR

HIGH-LEVEL CONVEYORS

LOADING BAY

ENERGY CENTRE(WATER TREATMENT)

BOILERS

PRODUCTION HALL

SUGAR DISSOLVING

WASHDOWN AREA

OFFICEBLOCK

RECEPTION/FACTORYENTRANCE

EMPTY CANS WAREHOUSE

Packaging and labelling are carried out by ourcan manufacturer in the factory next door.

DEPALLETISERS

ENGINEERING WORKSHOP

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5

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LINE-6

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Mixing the drinks

Filling

Packaging

Labelling

Rinsing, filling and sealing

Quality inspection and coding

Multi-packing

Palletising and shipping

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2

3

4

5

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