When Americol BV decided to modernize its production, the objective was not simply to increase output.
It was to eliminate instability, gain full control over performance, and build a production platform capable of sustaining growth..
“Our previous line worked, but..”
Americol’s production manager explains, as volumes increased, small inefficiencies began to accumulate. Micro-stoppages, minor adjustments, synchronization issues between modules — none of them dramatic on their own, but together they affected our overall OEE and predictability.”
At higher throughput, weaknesses become visible. Stability during peak speed was no longer enough; the team needed consistency across the entire shift.
“That was the turning point.”
We realized we didn’t need just more speed. We needed controlled, repeatable performance. The installation of the Futureproof 120 line marked a decisive change. From the first days of operation, the difference was visible. The most noticeable improvement was stability. The line runs smoothly, without constant intervention. The process feels controlled rather than reactive. A major contributor to that shift was the puck-based transport system. By guiding each container in a controlled way throughout the entire process, the system eliminated the small instabilities that previously led to manual corrections and micro-downtime. “Before, bottles could shift slightly or lose alignment, which meant small stops or operator adjustments. With the puck system, containers remain stable from start to finish. They don’t tip, they don’t move unpredictably. We’ve significantly reduced micro-stoppages related to transport.
“We didn’t want a solution for today only.
We wanted a platform for growth.”
The impact on performance indicators was immediate. Availability improved, downtime decreased, and OEE stabilized at a higher level. But the biggest change is consistency,” the team emphasizes. “We’re not chasing peak speed anymore. We maintain a stable output rate throughout the shift. That predictability has real business value. Integration between filling, labeling, case packing, and palletizing also plays a crucial role. Rather than operating as separate mechanical islands, the modules communicate as one synchronized system. “It feels like a single platform. There’s no accumulation pressure, no hesitation between stages. That seamless integration reduces complexity and simplifies troubleshooting.” Capping performance was another key factor. Americol works with trigger components that do not always have perfect dimensional consistency. In many systems, such variability creates risk.
The system clearly shows deviations.
There’s no guessing. Operators manage the process instead of reacting to unexpected behavior.
That level of transparency translates into independence. Americol estimates that the vast majority of minor issues — up to 95% — are resolved internally. Remote diagnostics through PackOS and CCTV provide an additional layer of security, allowing engineers to access real-time data and shorten troubleshooting cycles.“We solve most situations ourselves, but knowing that remote support is immediately available adds confidence. It protects uptime.” In parallel, Americol introduced 3D printing for selected format components. Instead of waiting weeks for mechanical parts, the team can design and produce certain elements internally within hours or days”.
“That flexibility shortens lead times and allows us to adapt faster when launching new products. It gives us control over our own upgrade cycle.”
From a business perspective, the most significant change is predictability. Planning has become more accurate. Resource allocation is more efficient. Unplanned downtime has decreased. “The total cost of ownership improved because the line runs consistently. Stability lowers operational stress across the board.” Scalability was equally important. The architecture of Futureproof 120 allows Americol to increase output without fundamental redesign.
“We didn’t want a solution for today only. We wanted a platform for growth. This system gives us that confidence.”For Americol, the modernization was not about automation for its own sake. It was about control, repeatability, and performance
stability at scale.
Flexible Lines
Futureproof 70
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Menno Trapman
Managing Director, Americol
