IDL Doubles Canning Line Output with Integrated Beverage Packaging Automation
Updated: Sep 21
When IDL introduced a second, higher-speed canning line at its Victorian beverage manufacturing facility, its manual end-of-line processes could no longer keep pace.
Fibre King designed and delivered an integrated conveying, multipacking, case packing and palletising solution that increased line output from 4,800 cans per hour to an average of approximately 10,000 cans per hour—all within a highly constrained production space.
Project Overview
Customer: IDL
Location: Moorabool Valley, Victoria
Industry: Beverage manufacturing
Application: Canned wine, spirits, cider and ready-to-drink beverages
Products handled: 250 ml slim and 330 ml sleek cans
Equipment: Product conveying, WestRock multipacker integration, Fibre King WAP25 case packer and Compact Modular Palletiser
Result: Output increased to approximately 10,000 cans per hour
The Problem: Manual Packing Was Restricting Line Capacity
IDL is a family-owned beverage solutions provider supporting the production and packaging of wine, spirits, cider and ready-to-drink products. As its product range and production requirements expanded, IDL installed a second, higher-speed canning line. However, the manual processes at the end of the line created a significant bottleneck. Operators were manually transferring multipacks into cartons and placing the completed cartons onto pallets. This restricted the capacity of the new line, increased manual handling and made it difficult for IDL to achieve the flexibility required for different products and can formats.
The available installation area created another challenge. The equipment needed to fit within a small space previously used as a cool room, with existing floor angles, drains and infrastructure limiting where machinery could be positioned.
IDL needed an integrated beverage packaging solution that could:
Keep pace with its higher-speed filling line
Reduce manual packing and palletising
Accommodate different can and multipack formats
Integrate with the existing filler and WestRock multipacker
Fit within the constrained production area
Provide capacity for continued production growth
The Solution: One Integrated End-of-Line Packaging System
Fibre King assessed IDL’s product formats, production rates, existing equipment and available floor space before engineering the system around the facility.
“All the equipment was designed…to fit a very small footprint.”Emily Wright, Victorian Sales Engineer — Fibre King
The completed solution connects each stage of the packaging process, from the filler through to the finished pallet. Cans leave the filler in single file before moving into a controlled mass-flow conveying section. They are then divided into two lanes and presented to the existing WestRock multipacker. The WestRock equipment produces four-pack and six-pack formats, which are automatically transferred to a Fibre King WAP25 wraparound case packer. The WAP25 groups the multipacks and loads them into cases before the completed cartons continue to a Fibre King Compact Modular Palletiser for automatic palletising.
The integrated solution includes:
Single-file and mass-flow can conveying
Controlled two-lane presentation to the multipacker
Integration with the existing filler and WestRock multipacker
Automatic handling of four-pack and six-pack formats
Fibre King WAP25 wraparound case packing
Compact automatic palletising
A layout engineered specifically for the available footprint
By coordinating the conveying, multipacking, case packing and palletising processes, Fibre King removed the manual handling points that had been limiting the performance of the line.
For IDL, selecting a supplier capable of integrating multiple machines within the restricted space was critical to the project.
“The solution that Fibre King came up with was perfect for all our requirements.”Andrew Byers, CEO — IDL
The coordinated system addressed IDL’s immediate capacity constraints while providing the flexibility required to support a growing mix of beverage products and packaging formats.
The Result: Higher Output in the Existing Footprint
Following the installation, IDL increased production from 4,800 cans per hour to an average of approximately 10,000 cans per hour.
The automated system enabled the company to use more of the capacity available from its higher-speed canning line while reducing its reliance on manual packing and palletising.
IDL also gained the flexibility to handle multiple beverage and packaging formats, including 250 ml slim and 330 ml sleek cans. This supports its broader product mix across wine, spirits, cider and ready-to-drink beverages.
Key Outcomes
Average line output increased to approximately 10,000 cans per hour
Reduced manual carton packing and pallet handling
Improved coordination between filling, multipacking and end-of-line equipment
Automated handling of multiple can and multipack formats
More effective use of a constrained production area
Additional capacity to support future product and volume growth
Packaging Automation Engineered Around the Production Line
This project demonstrates what can be achieved when each part of the packaging process is designed to operate as one coordinated system.
Rather than treating conveying, case packing and palletising as separate processes, Fibre King engineered the complete end-of-line solution around IDL’s products, production targets, existing machinery and site constraints.
The result is a compact, integrated system that allows the filling line to operate closer to its intended capacity and gives IDL a stronger platform for future growth.
Planning an Upgrade to Your Beverage Packaging Line?
More formats, higher throughput or too much manual handling at the end of your line?
Tell us what you are producing, how fast it needs to run, the formats you need to handle and the site constraints we need to work with. Fibre King will develop a practical automation concept with an indicative budget and delivery timeframe.
Talk to Fibre King about your next beverage packaging automation project.
Call 1300 831 330 or contact our automation team.
