Three aseptic lines in three years

Anyone who likes variety will love South Korea, and that goes for food and drink alike. The domestic market offers an array of beverages that is well-nigh unrivalled in terms of diversity. Even in the smallest of the ever-present convenience stores, you will find a huge choice of thirst-quenchers in bottles and cans, ranging from cold coffee-based drinks to barley mugicha, a tea made of roasted barley grains. No doubt about it – variety is king here! In 2022, South Korea was among the top three countries in the Asia-Pacific Rim with the greatest number of patented non-alcoholic beverages. 

And the Samyang Packaging company certainly contributes to that variety. “We’re currently filling more than 50 different products on our recently installed aseptic line alone,” says Kwang-nam Kim with a distinct note of pride. He is the team leader responsible for this line in production. Its commitment to diversity and quality has made Samyang Packaging the biggest contract manufacturer for beverages in South Korea. 

We’re filling more than 50 different products on our recently installed aseptic line alone. Kwang-nam KimTeam leader in production

All good things come in threes

A total of seven bottling lines are up and running on 100,000 square metres in the plant at Gwanghyewon, roughly one and a half hours’ drive away from Seoul. Samyang Packaging is setting benchmarks in the beverage industry, not least with its three state-of-the-art PET-AseptBloc L lines from Krones. Since 2021, two of them have been working nonstop in order to meet rising demand, and in 2023 another brand-new line was added to create a veritably impressive trio. 

Wide selection to suit every taste

Samyang Packaging decided to install a third line in order to meet rising demand and provide even more flexibility in the filling operation. “And that’s precisely what the new line enables us to do: respond promptly to changing requirements, thanks to fast change-overs and a high degree of automation,” says a gratified Kwang-nam Kim. The contract manufacturer fills a huge beverage portfolio here, ranging from juices to teas and coffee, at a speed of 40,000 bottles per hour. The minimum order quantity for Samyang’s customers on the new line is 400,000 units. That permits efficient, cost-effective handling of all purchase orders. Combining efficiency with diversity, Samyang Packaging is able to offer a huge processing spectrum of PET bottle sizes, ranging from 230 millilitres right up to generous 1.8 litres. All customers will find exactly the right format for their product here. “And that’s how we can meet each customer’s individual needs,” says Kwang-nam Kim. 

Labelling and packaging on the double

After the bottles have been meticulously filled, the next process step takes place in the dry end. First, the bottles are spaced out and then they are labelled on two Sleevematic machines, each with a downstream Shrinkmat shrink tunnel. After that, two Variopac Pro machines form different types of pack. Whether it’s six, twelve or 24 PET bottles in a shrink pack – variety is a top priority here, too. The six-pack is particularly popular, with four of these then put in a cardboard box. The packs are produced on two packaging systems, after which they are brought back together in the Modulpal Pro machine. Here, layer pads are inserted between the packs to ensure optimum safety during transportation. 

Invariably on the right track

System Logistics have played their part in ensuring the new line’s efficiency by ensuring that all materials are always in the right place at the right time. The Krones subsidiary delivered state-of-the-art automated guided vehicles (AGVs), which transport everything that is needed in the line, from preforms and labels right through to cardboard boxes. “This is a first for us: gaining some experience with integrating AGVs into our work flow. It used to be fork lift trucks that supplied the line with the requisite materials. So this marks the start of a new era for us, perfecting our process sequences even further,” says Jung-gyun Woo, another team leader in Samyang Packaging’s production.

Invariably on the right track – That goes not only for the AGVs but also for Samyang Packaging and Krones: The two companies have jointly travelled along an impressive path of innovation and cooperation in the more than 15 years of their partnership. Ever since the first stretch blow-moulding machine was installed in 2010, they have reached several important milestones together. Without a doubt, installation of the three aseptic lines marks the highlight of this long-standing collaboration. “Using several turnkey lines from the same manufacturer makes our operators’ work significantly easier, and that in turn further upgrades the lines’ efficiency and productivity,” says Jung-gyun Woo. 

Sustainability is yet another connective for the two companies. Samyang Packaging, for example, aims to render its production operation carbon neutral by 2050. Its sustainability strategy includes a focus on PET bottle lightweighting, so that production will become even more efficient and more sustainable. Kwang-nam Kim is sure Krones will provide the requisite solutions for this task as well, thus enabling Samyang to reach its targets.

Using several turnkey lines from the same manufacturer makes our operators’ work significantly easier, and that in turn further upgrades the lines’ efficiency and productivity. Jung-gyun WooTeam leader in production