Powertrain Solutions Optimizes Beverage Bottling Line Increasing Throughput By 200+%.
Bottling Line Efficiency Challenges
A leading beverage industry OEM faced beverage bottling line challenges while using a multi-head piston filler system and approached Stearns™, a Regal Rexnord brand, for a direct product replacement. While piston fillers work well for single-size fills, they lack the flexibility to accommodate varying container sizes efficiently. This limitation created production bottlenecks, as the customer needed a more adaptable solution to allow different fill volumes on the same production line without the constraints of their current system.
Additionally, the existing system required rapid start-stop cycles to maintain high-speed production. However, standard motors are not designed for such frequent cycling, leading to premature motor failures every six months, along with excessive maintenance and downtime. These issues negatively impacted industrial efficiency and overall throughput optimization, as frequent failures disrupted operations and increased costs.
The fill amount and time were so small and fast that normal motors couldn’t handle the cycles without excessive heat generation and subsequent premature failure, further compounding the OEM’s beverage bottling line challenges.
Case Study Overview: 200% Throughput Increase
We were able to increase cycle time from 5–6 cycles per minute, previously limited by heat generation, to 12 cycles per minute. This delivered a throughput improvement of over 200%. This advancement significantly boosted beverage manufacturing efficiency, enabling faster production without compromising reliability or motor performance.
Powertrain Components Driving Optimization
Rather than simply providing a one-to-one replacement, the Regal Rexnord Powertrain Solutions team took a holistic approach. By evaluating the customer’s operational needs, they identified an opportunity to optimize the process using Regal Rexnord’s broad portfolio of industry-leading product brands.
Grove Gear® Gearbox
The Grove Gear gearbox delivers the necessary torque transmission and durability for continuous operation, making it one of the most durable gearboxes for bottling applications. Its robust design ensures reliable performance under demanding start-stop cycles, helping maintain efficiency and minimize downtime in high-speed production environments.
LEESON® Flex-in-1 Motor
Designed for reliability and efficiency under high-speed cycling conditions, the LEESON motor is one of the most trusted energy-efficient motors for demanding applications. Its robust design makes it an ideal high-speed motor for bottling, ensuring smooth operation, reduced heat generation, and long service life even in rapid start-stop environments.
Stearns® Clutch
Engages only during rapid fill cycles, eliminating unnecessary strain on the motor. The Stearns clutch functions as a precision clutch system, providing smooth engagement and disengagement to protect critical components. This motor protection clutch helps extend motor life, reduce wear, and maintain consistent performance in high-speed bottling operations.
Operational Benefits and Performance Gains
A standard motor cannot sustain such rapid cycles without experiencing excessive wear and failure. However, this integrated system allows the pump motor to run continuously, while the clutch engages only during the fill process. This design significantly improves bottling line performance, delivering:
- Instant full-speed and torque operation
- Reduced motor wear due to elimination of frequent start-stop cycles
- Precision control for varying container sizes
- Added energy savings through optimized operation and reduced heat generation
Impact on Beverage Manufacturing Operations
Cross-functional collaboration ensured that each part of the system, the motor, gearbox, and clutch, was engineered to work together, resulting in:
✔ A fully integrated, high-performance solution that drives operational efficiency across the bottling line.
✔ Improved beverage production ROI by reducing replacement costs and eliminating premature motor failures, extending equipment lifespan and lowering long-term expenses.
✔ A simplified, modular design that allows for easy adjustments to accommodate different fill sizes, eliminating the need for multiple dedicated piston systems and improving bottling line uptime.
✔ Minimized unplanned failures thanks to a clutch-driven approach that removes excessive strain on the motors, significantly reducing downtime and delivering substantial maintenance reduction benefits.
Why Regal Rexnord for Bottling Line Solutions
Through partnering with Regal Rexnord industrial solutions, this beverage OEM transitioned from a rigid, failure-prone system to a flexible, high-efficiency solution that supports their fast-paced production needs. By leveraging integrated powertrain systems and working with true bottling line experts, this approach not only solved their immediate challenges but also future-proofed their operations, ensuring they can handle varying fill sizes, high-speed cycles, and long-term reliability, all while reducing costs.
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Conclusion
By partnering with Regal Rexnord, this beverage OEM overcame critical bottling line efficiency challenges and achieved a remarkable 200% throughput improvement. Through an integrated powertrain solution featuring Grove Gear® gearboxes, LEESON® motors, and Stearns® clutches, the system delivered superior flexibility, precision control, and energy savings while reducing motor wear and maintenance costs. This collaboration not only optimized beverage manufacturing efficiency and bottling line uptime but also improved ROI and future-proofed operations for long-term success. Regal Rexnord remains the trusted choice for bottling line experts committed to driving operational excellence.
TCO Savings (Over 7 Years) |
|
| Current Solution | Proposed Regal Rexnord Solution |
| Cost | |
| Specialty Configured 8 Pole Motor: $500 each |
Grove Gear® Gearbox, LEESON® Flex-in One Motor, Stearns Clutch: $2,800 |
| VFD $500 each | |
| Replacement | |
|
Motor = 0.5 years $7,000 VFD = $3.5 years $1,000 |
7 years $2,800 |
| Total Cost: $8,000 | $2,800 |
| Total Savings: $5,200 | |
|
We were also able to increase cycle time from 5-6 cycles per minute, limited by heat generation, to every 12 per minute, increasing throughput by 200+% |
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Industry Applications and Case Studies
Challenge
A manufacturer was sourcing power transmission products from five different suppliers. Each vendor had its own pricing, shipping fees, and payment terms, creating inefficiencies in the supply chain. For each application, the manufacturer had to issue five separate purchase orders and manage five individual shipments, which complicated processes for industries like mining equipment logistics and food industry automation.
Regal Rexnord Solution:
Regal Rexnord Solution: Switching to Regal Rexnord meant consolidating five vendors into one. This streamlined the supply chain, reduced complexity for applications in powertrain systems, and improved the entire procurement process. The company saved $304,000 annually.