| After driving to the Ball Packaging Europe can manufacturing plant, centrally sited at Rugby, members of the BBI were rewarded with a thoroughly interesting presentation and tour of the production lines. The plant is a classic ‘hole-in-the-wall’ can-making operation originally built to supply the adjacent Britvic Factory.
Steve Wilkinson, Factory Manager, hosted the visit, which took place on the 19th October.
On opening the proceedings Steve gave us a very informative technical presentation, after initially explaining that the site has operated for 16 years as a ‘hole-in-the-wall’ operation, commencing production in 1988, and after two previous ownerships was purchased 2 years ago by Ball Packaging Europe. In year 2000 the site was converted to two high-speed lines running respectively at a maximum of 1750 and 1800 cans per minute on 33, 44 and 50 cl. cans and giving the same capacity as the three previous production lines.
The technical part of the presentation covered the complete manufacturing process from rolls of sheet steel to the finally decorated can. It included stamping out the cup, extruding the wall to the required thickness, necking to accommodate both 206 and 202 ends, washing thoroughly and applying base coat, decorating using the offset process and final lacquering.
Of course, a great deal of attention is paid to quality control with a camera making continuous checks for shape and a light source continually checking for pinholes. Samples are taken off lines at hourly intervals for compete checks and steps are in hand to automate this process.
The tour of the plant revealed just how automated this process is and to ensure final quality the cans are palletised on plastic pallets and strapped between cardboard layer pads. The site operates 24 hours per day 7days per week and employs 140 team members on continuous shifts. As well as feeding “through the wall” the plant also supplies other customers and suitable warehousing has been constructed to accommodate the necessary buffer stocks.
Our thanks are to Steve Wilkinson and his team for providing an excellent visit and fine hospitality all rounded off by a buffet lunch. On behalf of BBI members John Yates, National Chairman, congratulated Steve on the high standard of the visit and also expressed thanks to for a very interesting presentation and tour of the plant.
We were left with the impression that this operation is an excellent example of efficient can manufacture, it is a clean and hygienic plant that produces National Branded products to high quality standards, designed to satisfy customer needs.
Brian Gibbs.
Southern Section Coordinator.
The British Bottlers’ Institute.
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