East Coast brewery improves beer packaging process

Fast-growing brewery meets production demands with innovative hot melt packaging technology

To improve its beer packaging process, Two Roads brewery installed Graco’s InvisiPac® Tank-Free Hot Melt System. By doing this, they managed to improve production efficiency, reduce waste by reducing box pop-opens, and save up to 20% of energy resources.


 

 

To support its ongoing growth, Two Roads Brewery needed a reliable and effective packaging line. To meet production schedule requirements, ensure carton product quality, and ensure the correct amount of adhesive, it turned to Graco.

121,000 barrels a year

Connecticut-based Two Roads Brewery is one of the fastest-growing craft breweries in the northeast. Since beginning operations in 2012, Two Roads has increased production to 121,000 barrels a year. Production efficiency and consistent sealing application for product quality are critical elements for continued success at this level.

Getting the right seal

Delivering cases that remain sealed calls for a hot melt delivery system, to ensure the correct amount of adhesive application that adequately seals the top and bottom of each carton. The legacy hot melt delivery system took nearly an hour to heat up, putting pressure on the production schedule. In addition, Two Roads Brewery was experiencing char, which is by far the biggest problem in any hot melt application system.

Discover how you can reduce the maintenance costs of your hot melt system.

A new hot melt delivery system

To increase efficiency, meet production schedule requirements, and ensure carton product quality, Two Roads Brewery installed a new hot melt delivery system: Graco InvisiPac® Tank-Free Hot Melt System. It includes revolutionary new melting design and technology specifically designed to improve production efficiency by stabilizing glue consumption rates and reducing both adhesive waste and waste in the form of boxes that need to be repacked or resealed because of an inadequate seal. The new InvisiPac® Tank-Free system also reduces downtime and frees up operations personnel for more productive tasks.

Learn how to minimize maintenance operations of your hot melt system.

Improved production efficiency

The InvisiPac® Tank-Free Hot Melt System dramatically improved Two Roads Brewery’s production efficiency by stabilizing glue consumption rates and reducing adhesive waste, while reducing startup time to under 10 minutes to support 8am production line starts. InvisiPac® also reduced waste in the form of boxes that need to be repacked or resealed because of an inadequate seal. And last but not least: it delivered a 20% reduction in energy use when compared to a specific competitor’s unit – resulting in a healthier bottom line.

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Specifications

  • End-user: Two Roads Brewery
  • Industry market sector: Food and drink

Challenge

  • Increase efficiency, meet production schedule requirements, and ensure carton product quality
  • Deliver quality beer packages with the correct amount of adhesive
  • Reduce adhesive char

Solution

  • Graco InvisiPac® Tank-Free Hot Melt System

Result

  • Improved production efficiency
  • Improved quality control
  • Resource savings

Keys to success

  • Graco’s InvisiPac® stabilizes glue consumption rates and reduces adhesive waste, while reducing start-up time to under 10 minutes to support 8am production line starts
  • The new InvisiPac® Tank-Free system has also reduced downtime and freed up operations personnel for more productive tasks

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