DECEMBER 2025
Digitizing the plant seemed like the solution. And in some ways, it is. Sensors everywhere, machine connectivity, real-time reporting, dashboards… everyone talks about Industry 4.0 as if it were a magic button that prevents breakdowns, reduces waste and boosts productivity.
But in many bottling lines, the reality is different: the plant has been digitized… and yet unplanned stoppages keep happening. Sometimes even more frequently than before.
Why? Because the real issue wasn’t just a lack of data. It still is — and always has been — a lack of timely, actionable decisions. Most companies have more information than ever, but data alone does nothing. If there are no alerts to anticipate risks, data is useless. If it doesn't reach the right decision-makers, it’s useless. If plant staff don’t trust or understand it, it’s useless. If it isn’t connected to quality, maintenance or inventory, it’s still useless.
This is what many manufacturers are now facing: more technology, same decisions. Which means: same errors, same stoppages.
A rejected batch. A truck waiting. A client who never comes back. In a bottling line, every stoppage has consequences. Not just in production, but also in reputation, margins, and team performance. And the most frustrating part is that many of these incidents are preventable. But they aren't avoided because systems don’t translate data into action. Or no one is monitoring the right indicators. Or, when they are, it’s already too late.
Digitizing a line doesn’t just mean connecting machines. It means turning the production system into an intelligent ecosystem where everything is linked. Where the machine sends alerts before a failure. Where maintenance sees the issue in real time. Where quality understands the impact. Where production can anticipate a stoppage or adjust cycle times. Where inventory knows when to replenish or when to stop producing.
True digitization means preventing issues, not just recording them. It means enabling data to flow, to be visible, and to lead to action. It means the system supports the team. And above all, it means the right data reaches the right person, at the right moment.
This isn’t about more sensors, more dashboards, or more screens in the operations office. It’s about creating a line that doesn’t stop. A line where unplanned stops are no longer surprises, but decisions. Where failures are detected before they happen. Where people no longer rely on a senior operator’s intuition or an outdated spreadsheet. Where production flows with traceability, consistency, and confidence.The real challenge isn’t technological — it’s cultural. It’s about changing how decisions are made. In many companies, systems have been installed without changing mindsets. Teams are still reacting instead of anticipating.
But in a modern bottling facility, that’s not enough. Brands demand traceability. Consumers demand consistent quality. Logistics demand punctuality. Markets demand flexibility. And all of that only works when decisions are made earlier — not later.
If your line is still stopping, then it’s not truly digitized. At least not in the way it should be. Digitization isn’t about buying technology. It’s about transforming how you operate. And that starts with asking an uncomfortable question: Are our data helping us decide in advance… or just explaining what already went wrong? If the answer isn’t clear, maybe you don’t need more sensors. Maybe you need to rethink how you're using the data you already have.
At Irundin, we’ve been asking ourselves this same question. Not just to design smarter machines, but to help our clients make better decisions. Because bottling faster isn’t enough. What matters is keeping the line running.