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- FMCG
Lightweight Change Parts
Asahi Cuts Downtime with 40% Lighter Change Parts and Safer Handling
Faster changeovers = reduced downtime
lighter change parts from ~13kg to ~8kg
Reduced risk of injury and OH&S claims
Two-piece modular design for ease of handling and storage
The Challenge
Asahi’s bottling line teams at the Tullamarine plant were working with heavy OEM change parts, increasing:
Manual handling risks
Changeover time
Strain on an ageing workforce
Asahi needed a partner who could deliver:
Lightweight but durable container handling components
Easy-to-use modular designs
Improved OH&S outcomes without sacrificing performance
The Solution
Alternative Engineering:
Conducted on-site measurement and consultation using ROMER Arm 3D scanning
Reverse-engineered Asahi’s existing parts into a modular two-piece design
Used blended high-strength lightweight materials to reduce component weight
Delivered change parts with quick-release mechanisms to speed up swaps
AE’s engineers worked side-by-side with Asahi’s production and OH&S teams to ensure solutions were aligned to plant needs, safety protocols, and ergonomic handling standards.
Outcome
| Metric | Result |
|---|---|
| Weight Reduction | ↓ 40% lighter parts (~8kg per set) |
| Manual Handling Risk | Reduced risk of strain/injury during changeovers |
| Changeover Time | Significantly reduced due to faster handling and install |
| OH&S Compliance | Met internal safety improvement targets |
| Worker Satisfaction | Easier to lift, store, and manage parts on-site |
<< Trusted By >>
Struggling with heavy OEM parts or slow changeovers?
Alternative Engineering can help you design lighter, faster, and safer change part systems tailored to your bottling line.
