t the new installation, the Krones technology, as well as the range of distinctive, new bottles is of the highest standard and likely to accelerate what has already been spectacular growth of around 30% annually since 2002.James Cain, Chief Executive of Harrogate Spring Water, said of the latest developments, “Our plan since my father started the company twelve years ago was always to develop high quality brands. We know our water source is among the best in the UK and has achieved international recognition. We’ve won many awards for both our still and sparkling waters, including ‘Best Sparkling Water in the World’. Our packaging for both glass and PET bottles has been updated and the new PET diamond design, we believe, is quite stunning. It has been ‘right-weighted’ - ensuring the packaging weight is optimised to limit our carbon footprint, whilst maintaining the same characteristics and high performance. Our strategy has always been to provide a premium product, whilst making it accessible and appealing to all. The new designs certainly provide exceptional stand-out and will hopefully take us to the next level.”
James continued, ”We are fortunate to have many of the best suppliers within our locality. We have remained loyal to the same suppliers over the past twelve years; Ardagh Glass, Esterform for bottles and preforms and Bericap for closures. This close relationship has enabled the design team at Krones in Neutrabling to create a PET bottle that looks stunning, performs well and has achieved tremendous feedback from our customers.”
Harrogate, the original British spa town, was the first to bottle water in 1740. By 1914 it was the biggest exporter of water, proudly keeping British troops hydrated both in the UK and as far away as Bombay. Harrogate became a regular and favourite destination for the Russian Royal family; exports to Russia now continue to develop, with the Russian President Vladimir Putin also a fan.
The 23,000 sq ft extension doubles the existing area and houses the new line, as well as some warehousing. The existing combi glass/PET line will continue to produce glass.
When setting up the new factory twelve years ago, Harrogate Borough Council had aspirations for the building to also act as a visitor centre within the conservation area. As such the offices and meeting rooms have been beautifully designed and fit in sympathetically with the surrounding landscape.
James commented on his decision to go down the Krones route with a complete Krones turnkey supply, ”There are some other good suppliers around, however having visited many installations to view their equipment we felt Krones were a perfect fit and partner for the project. We knew from the outset we would have great support from the Krones UK team and also from their colleagues in Germany. Although the extension is significant, space remains at a premium. The design of the production line has been optimised to utilise the available area most effectively. The Krones Ergobloc, the first in the UK, saves on footprint and space; an incredibly efficient layout allows us to run with just three operators.”
Whilst the company produce still and sparkling water for both the Harrogate Spring and Thirsty Planet brands, the option for Thirsty Planet to add flavoured waters to its product portfolio in the future is an option as part of the Krones installation, including a Contiflow mixer for both still and sparkling products.
The line comprises an Ergobloc L with a 16 cavity Contiform C316 blow moulder, a Prontomodul 720-18 modular labeller with high speed wrap around labelling station and a Modulfill VFS 2520-84-94 volumetric filler all running at up to 36,000 bottles per hour. The filled bottles are then packed using a Variopac TFS60 film only or tray and film shrinkwrapper, with Krones palletising.
The Ergobloc L design is very compact, labelling straight after the blower reduces the conveyors and the line footprint is reduced by 50% compared to a standard line. One operator can look after the Ergobloc and the packer behind him. A reduction in maintenance will be achieved as the line operates using less materials and energy.
Within the first week of performance tests after installation, the line achieved an unprecedented 94.42% efficiency over 8 hours running on sparkling Harrogate Spring water, an efficiency that is world class.
James summed up the project, ”It has been both exciting and challenging! During the development and installation of the new line, we have continued to grow sales, ensured our staff have received thorough training, we’ve designed the new bottles, closures and labels, arranged for extra power to the site and I’ve also got married in that time too! It has all been quite a juggling act. We could not have achieved any of this without a great team, the support of our suppliers and of course Krones, who have been quite superb.
Exports feature highly for us with our overseas customers appreciating the premium quality of our brands together with those in the UK and I believe we are now well equipped for the next stage of our growth plans.”
