This was a popular visit with 36 applying for only 25 to 30 places. It is always difficult to know how to play the numbers game, but as usual we had those with sudden commitments so we ended up with a tidy 27. This was three visits in one with the opportunity to see state of the art glass manufacturing, warehousing (biggest in Europe) and glass packaging lines.

Peter Fitzgerald, Sales and Marketing Director, opened proceedings by telling us how Sean Quinn was once a lowly farmer, but was not too fond of farming life. When doing some building work he was not impressed with the quality of service when ordering building materials. When Sean found that his farm had many of the materials that he could quarry for building purposes, he successfully took on the other suppliers with the ethos of ‘same day delivery’ which proudly stands by today.

John Aitken, Operations Manager, and Peter told us how the investment at Ince was major – grants amounted to about £9.9M against a total investment of £280M. Quinn has built two 600 tonne furnaces and will have 13 production lines producing 370,000 tonnes of glass per annum (or 1.2 billion container!). The warehouse is hugely impressive occupies 13 acres and can hold 281,300 pallets. It is totally automated, and we were privileged in being able to see the automation at work. The carriages which carry the lifts are vast and move noiselessly down their corridors to the far end of the building. The travel is further than the eye can see. A carriage deposits or picks up a pallet and returns back to its station. Due to the automation, Customs and Excise took some persuasion to accept the figures. However, after a few random selections they were convinced, and this is how they now check the stock records!

The furnaces are controlled using the most up to date technology, and the air pollution is also taken care of using the best available filtration plant to ensure that the emissions are clean before being released into the atmosphere. The glass lines are impressive, and are fitted with the latest inspection systems. We saw a line with ten Independent Section (IS) triple gob machines set up for NNPB (Narrow Neck Press and Blow) and producing flint bottles. All bottles produced go to the warehouse whether they are for internal use on the packaging lines, or for external use by customers.

The Packaging Hall has been sized to take 5 packaging lines (4.5 football pitches). Lines 2 and 3 have been completed. Line 2 will handle bottle sizes of 0.5 to 1.5 litres for wines and spirits, and will run at 24,000 bph for 0.75 litre bottles. Line 3 will handle bottle sizes of 18.75 to 70cl for carbonated products, and will run at 60,000bph for 33cl bottles. Krones have provided these lines at the top end of their specification for all machinery. This should cater for the most challenging of any contract customers requirements.

Accumulator and Filler

The line layouts are ‘U’ shaped with product supply on one side of the building and pallet movements on the other. LGVs (Laser Guided Vehicles), which will handle the pallets, have yet to be installed.

Preparation Room

The product handling area is fitted out with the best available equipment which has been supplied by GEA. This allows controlled blending and dilution as required and everything is CIPiable. The only flexible hoses in use are on the intake bay. Tank sizes are 300 and 600 hl.

The whole packaging area is well lit and the routing of cables and drains well thought out. In all it puts contract packaging into another league! The operation will handle 600M units per annum.

Palletiser Area

Quinn have employed loyal staff with aptitude, and have chosen to undertake the specialist training themselves. They work 12 hour shifts.

After an extremely enjoyable trip, thanks were given to our hosts Peter Fitzgerald and John Aitken, and their team of Tony, David, Jan and Peter T for their time. Thanks was also given for the welcome coffee on arrival and the excellent buffet lunch. Many emails have been received praising the visit.

It was clearly one of the best visits that the BBI have ever arranged and will be remembered well into the future. Many thanks to Quinns for a great day!

Report by Jeremy Browne