Tanzania Breweries Limited (TBL) in Arusha successfully completed a complete packer unpacker machine upgrade to fix ongoing operational problems. Specifically, the project involved updating PLC and HMI systems for their packing equipment. This important work stopped frequent faults and production stops. As a result, this strategic packer unpacker machine upgrade has brought back reliable operations and better brewing efficiency.
Need for Equipment Updates
The packer/unpacker process had repeating faults that hurt packing and unpacking work. These problems greatly affected brewery output and caused much downtime. Unexpected stops due to equipment breakdowns happened often. Each stop meant lost production time and higher operating costs. Also, late deliveries affected customer happiness and business results.
Old Control Systems
The existing control units had reached their end-of-life and became outdated. As technology improved, finding matching spare parts got harder. This lack of parts caused repair delays that made downtime worse. Therefore, a full packer unpacker machine upgrade became necessary for continued operations.
Complete Upgrade Process
Full System Check
First, we did a complete check of the existing packer/unpacker systems. Our team studied operational drawings and found specific problems to fix in the new system design.
Modern Control Selection
We chose new Siemens PLC and HMI systems that offer better reliability and modern features. Important choice factors included easy setup, available spare parts, and full support services.
Careful Installation Plan
Next, we carefully planned the installation to reduce production problems. We arranged the removal of old units and setup of new Siemens control systems.
Thorough Testing Process
Commissioning involved complete testing to make sure all parts worked right. Our automation team did overnight on-site testing to ensure smooth change and fix past issues.
Full Staff Training
Finally, we trained TBL staff on using the new machines. This knowledge sharing ensured proper system use and maintenance skills.
Important Upgrade Benefits
Better Operation Reliability
The new systems have greatly reduced faults and errors. This improvement ensures steady operations with fewer unexpected stops and consistent production flow.
Less Production Downtime
Modern equipment with available spare parts has much decreased downtime. As a result, more uptime has raised overall output and productivity.
Improved Process Control
Advanced control features allow exact control and monitoring. These abilities improve quality control, optimize cycle times, and reduce material waste.
Future-Ready Operations
The change from old to modern systems has fixed ongoing problems. This upgrade puts TBL Arusha in position for better productivity and continued growth.
Conclusion: Successful Change Achieved
This successful packer unpacker machine upgrade has changed TBL Arusha’s packaging operations. The updated systems deliver reliable performance, lower maintenance costs, and better production efficiency. This project shows IAES’s knowledge in providing practical automation solutions that solve real operational challenges. With this upgrade, TBL Arusha is well-set for continued success in Tanzania’s competitive brewing industry.
