Nestlé Pakistan Automating Mineral Water Level Control with JAHAANN

Client: Nestlé Pakistan

Industry: Food & Beverages

Service Provided: Industrial Automation – Water Level Control System

Content

The Problem
The Solution
Achievements
Conclusion

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The Problem

In mineral water bottling plants, accuracy in filling levels is non-negotiable. Nestlé identified multiple challenges in their existing system that required a more advanced water level control system:

Inconsistent Filling Levels
Manual or semi-automated processes often resulted in overfilled or underfilled bottles. This not only risked customer dissatisfaction but also affected compliance with Nestlé’s strict quality standards
Wastage of Resources
Every drop of water is valuable in high-volume production facilities. Overfilling caused wastage, while underfilling led to rejected bottles and reprocessing.
High Labor Dependency
Operators were required to manually monitor the process, which increased labor costs and left room for human error.
Inefficient Monitoring:
Without real-time visibility, detecting errors in the filling process took time, often after large batches had already been processed.
Production Delays:
Manual interventions and inconsistencies caused bottlenecks in the production cycle, directly affecting efficiency and output.

The Solution

JAHAANN partnered with Nestlé to design and implement a state-of-the-art water level control system using advanced sensors, automation controllers, and intelligent monitoring tools. The solution was structured around three core components: Ultrasonic Sensors, Photoelectric Sensors, and PLC Integration.

Ultrasonic Sensors for Precision

Objective:

Ensure that every bottle maintains a consistent and predefined water level.

Execution:

Sensors were placed strategically to detect volume. If the water level dropped below the set point, the system triggered an immediate corrective action.

Photoelectric Sensors for Presence Detection

Objective:

Prevent overflows and water loss in cases where a bottle was missing on the conveyor belt.

Execution:

The sensor confirmed bottle presence and communicated the signal to the controller, ensuring water was only dispensed when required.

PLC Integration for Centralized Control

Objective:

Automate the process, eliminate human dependency, and ensure seamless operation.

Execution:

The PLC received data from both ultrasonic and photoelectric sensors, processed it in real-time, and controlled the filling mechanism. The PLC also stored data logs for performance monitoring and future audits.

Achievements

The automation project delivered transformative results for Nestlé Pakistan. By adopting JAHAANN’s water level control system, the company achieved:

Consistency in Quality
Every bottle was filled to the exact same level, meeting Nestlé’s global quality assurance standards. This reduced customer complaints and ensured compliance with regulations.
Reduced Wastage
The system minimized overflows and underfills, saving thousands of liters of water annually. This supported Nestlé’s sustainability goals and lowered operational costs.
Improved Operational Efficiency
Automation reduced reliance on manual monitoring, speeding up production cycles and increasing throughput by approximately 30%.
Lower Costs
Reduced labor involvement and less reprocessing directly translated into cost savings for the company.
Real-Time Monitoring
With the PLC and sensors working together, Nestlé gained real-time visibility into operations, allowing managers to make data-driven decisions.

Conclusion

The Nestlé Pakistan project demonstrates how an advanced water level control system can transform traditional bottling processes into highly automated, efficient, and sustainable operations. By combining ultrasonic sensors, photoelectric detection, and PLC intelligence, JAHAANN delivered a solution that not only solved Nestlé’s immediate challenges but also created long-term value.