How bottler Refresco saves 45% on hot melt adhesive in their end-of-line packaging

“Initially, we were talking about 30% savings. But we accomplished to reduce our hot melt adhesive usage with 45%.” If you know that Refresco Iberia yearly packs 1.000 millions liters of soft drinks and juices, that is a lot of money. Operations manager Fidel Castello and engineering manager Josep Ferri Sanz explain how InvisiPac makes this possible.
 

Refresco is the world's largest independent bottler of beverages, with production sites in Europe, North America and Mexico. They have over 80 factories worldwide.

This case is situated in their end-of-line cardboard packaging in Refresco Iberia, Spain.

-45% hot melt adhesive usage, -40% electricity consumption

Juan Manuel Pizarro, Graco’s packaging sales manager: “We started out with two test units in one plant, now over 20 lines have been converted to InvisiPac. We are currently setting up an action plan for other Refresco sites.”

This success was driven by Josep Ferri Sanz and Fidel Castello, who took the lead in optimizing the processes. At Refresco Iberia, we achieved an impressive 45% reduction in hot melt adhesive usage across all our production lines, surpassing our initial target of 30%. Josep explains, “Additionally, we significantly reduced our electricity consumption by 40%. InvisiPac has proven to be a valuable asset, not only lowering costs but also making operations easier for our team, with less maintenance required from our technicians.”

“One of the biggest compliments we as a manufacturer can get, is what Josep Ferri Sanz mentions near the end of the video. One year after the installation, his colleagues on the factory floor have forgotten about the integration: the set-up process was that smooth.”

End-of-line packaging at Refresco Iberia.
 

Advanced display module (ADM).
 

Hot melt adhesive being dispensed.
 

A look at the set-up.