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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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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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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