Coca Cola Hellenic’s Lisburn facility successfully transformed their beverage waste management operations through innovative custom-designed processing systems. The implementation of specialized can baling equipment and integrated bottle processing solutions converted costly waste disposal into revenue-generating material recovery operations.
The Hellenic Coca-Cola site in Lisburn faced significant operational challenges managing beverage waste that was impacting both operational efficiency and cost management.
Time-Consuming Processes: Getting rid of beverage cans and bottles proved very time-consuming, creating operational bottlenecks and reducing manufacturing efficiency.
Labour-Intensive Operations: Manual handling of rejected products required substantial labour resources, increasing operational costs and reducing productivity.
High Disposal Costs: Traditional waste disposal methods created ongoing expenses without recovering any value from rejected materials.
Pressurised Container Issues: Bottles or cans requiring rejection and recycling were often full of pressurised fizzy drinks, creating safety and handling difficulties.
Unrealised Material Value: The facility recognised that aluminium cans and plastic bottles had inherent value, but lacked means to capitalise on this potential revenue stream.
Liquid Separation Problems: Processing full containers required effective liquid drainage and management systems.
After comprehensive consultation with Gradeall, two separate custom installations were designed to address the facility’s specific beverage waste challenges.
Specialised Can Baler Design: A new can baler was specifically designed to cope with the additional volume of waste cans that a large beverage company generates.
Integrated Drainage System: The can baler incorporated a large drainage sump and splash guards to safely channel away all leaking liquid from compressed cans.
Safety Features: Comprehensive liquid management prevents spillage and contamination whilst ensuring operator safety during processing.
Valuable Output: The system produces dense bales of aluminium cans suitable for sale to metal recycling processors.
Integrated Processing Line: A comprehensive system combining multiple technologies for efficient bottle processing.
Stainless Steel Conveyor System: Custom conveyor designed for beverage industry hygiene standards and operational requirements.
Bottle Shredding Technology: Specialised shredding equipment effectively separating liquid content from valuable plastic materials.
GH500 Horizontal Baler Integration: Professional baling system producing dense, saleable plastic bales.
Custom Control Interface: Touch screen control system managing all integrated systems through one user-friendly interface.
Comprehensive CAD Design: Detailed engineering drawings provided during design phase enabling precise planning and optimization.
Site Visualisation: Advanced imaging allowed fine-tuning of system configuration before final approval and installation.
Custom Engineering: Tailored solutions addressing specific beverage manufacturing requirements and constraints.
Liquid Separation: Effective separation of fizzy drinks from valuable plastic materials through controlled shredding processes.
Material Recovery: Production of dense bales of recyclable plastic suitable for manufacturing applications.
Revenue Generation: Conversion of waste disposal costs into material sales revenue.
Revenue Generation: The company now produces bales of aluminium and plastic which can be sold to processors, generating revenue rather than incurring disposal costs.
Cost Reduction: Elimination of traditional waste disposal expenses through on-site processing.
Labour Efficiency: Significant reduction in manual handling requirements through automated processing systems.
Operational Streamlining: Integrated systems reducing time and resources required for waste management.
“Gradeall were very helpful, explaining what would be involved from the very start of the design process. The CAD drawings and images of the site before we gave the go ahead were very useful and allowed us to fine tune things to how we wanted them to be. In the end we have a setup that is a lot less labour intensive and allows us to deal with the waste bottles and cans we end up with, the revenue generated from the finished bales significantly reduces the cost of waste management on site. General Manager, Coca Cola Hellenic Lisburn
“Gradeall were very helpful, explaining what would be involved from the very start of the design process. The CAD drawings and images of the site before we gave the go ahead were very useful and allowed us to fine tune things to how we wanted them to be. In the end we have a setup that is a lot less labour intensive and allows us to deal with the waste bottles and cans we end up with, the revenue generated from the finished bales significantly reduces the cost of waste management on site.
General Manager, Coca Cola Hellenic Lisburn
The Coca Cola installation demonstrates effectiveness across beverage manufacturing applications:
Similar applications across food and beverage manufacturing:
The installation demonstrates Gradeall’s expertise in regional manufacturing applications:
Gradeall International delivers comprehensive solutions with demonstrated success across beverage manufacturing applications:
For comprehensive beverage and food manufacturing waste management solutions that convert disposal costs into revenue opportunities, contact our manufacturing waste specialists.
Our specialised baling systems can transform your manufacturing waste operations with proven performance for demanding manufacturing applications.
Transform your manufacturing waste management with custom-engineered solutions that deliver operational efficiency whilst generating revenue from previously costly waste streams.
"Gradeall were very helpful, explaining what would be involved from the very start of the design process. The CAD drawings and images of the site before we gave the go ahead were very useful and allowed us to fine tune things to how we wanted them to be. In the end we have a setup that is a lot less labour intensive and allows us to deal with the waste bottles and cans we end up with, the revenue generated from the finished bales significantly reduces the cost of waste management on site."
Our customer focused sales team have a combined 100+ years in the recycling industry and have a deep understanding of the Tyre Recycling Industry and waste baling/compacting industry to ensure our customers are getting the best advice and products to improve recycling processes at their business.
Get in touch to see how we can help you today
+44 (0)28 8774 0484
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