How Beverage Manufacturers Are Using Technology to Boost Efficiency
Beverage manufacturers are under significant pressure to meet the evolving demands of consumers, who are increasingly seeking a diverse range of drinks. This has led to a rapid increase in product diversification, with thousands of SKUs entering the market each year. However, this diversification comes with its own set of challenges, particularly in terms of production complexity and efficiency.
Historically, the beverage industry has seen slower product development cycles, but advancements in technology and automation have accelerated these processes. Companies like Coca-Cola have gradually expanded their portfolios, but the rate of new product introductions has increased dramatically in recent years, reflecting shifting consumer preferences for beverages with added vitamins, proteins, and minerals.
One major challenge that manufacturers face with increased product variety is the complexity it adds to production lines. This complexity can result in higher risks of disruption, delays, and waste. Frequent changeovers are required for the variety of products, which incurs downtime and affects Overall Equipment Effectiveness (OEE). Furthermore, sustainability efforts, such as the 'lightweighting' of cans, present additional manufacturing challenges as production lines must adapt to new can weights.
Lineview's Global Benchmark Report 2025 highlights that up to one-third of losses on can lines occur between depalletisers and fillers, largely due to the fragility of lightweight cans. These losses contribute to waste, further complicating efforts to streamline production and sustainability.
To address these challenges, manufacturers are increasingly turning to technology and data-driven insights. By leveraging real-time data, factory teams can identify inefficiencies and optimize production lines. For example, a company with multiple production lines running at 50% OEE could increase capacity significantly by improving OEE by just 10%. This approach not only saves costs but also enhances sustainability metrics by reducing waste.
Using data tools to test micro-trends and limited-edition flavors allows manufacturers to adapt quickly to consumer trends without incurring high overheads. Predictive simulation tools further aid in testing different scenarios before making physical adjustments to production lines, thereby reducing the time from R&D to market.
While external economic factors are beyond the control of beverage manufacturers, optimizing internal production processes through data and technology can provide a competitive advantage. This requires ongoing collaboration and the effective use of emerging technologies to interpret data and drive long-term improvements.
