Technical Analysis and Solutions to Reduce Scrap Rate In Liquid Filler Machine: Case Study: In Moha Soft Drink Production Line

The carbonated beverage industry relies on automated filler machines for efficient production. Despite technological advancements, scrap generation and rejected bottles during filling remain a challenge, leading to product waste and quality control issues. This study focuses on the filler machine at the Moha Soft Drink Factory in Mekelle, where scrap accounts for approximately 3.85% of production, thereby reducing profitability. The research aims to identify the root causes of scrap, correlate key technical parameters of the filler machine, and propose solutions. Quality control tools, including Pareto and fishbone diagrams, together with statistical regression analysis, were employed. Data were collected through observations, focus group discussions (FGDs), interviews, and instruments such as flow meters, pressure gauges, and temperature probes to monitor variables including speed, pressure, and temperature, viscosity, and CO₂ levels. Pareto analysis revealed underfilling, uncrowned bottles, and contamination as the top contributors to scrap, accounting for 88.1% of total rejects. Root cause analysis and regression modeling identified counter pressure (bar) and speed (bph) as significant predictors of scrap rate, explaining 37.5% of its variability (p = 0.002). The regression coefficients for counter pressure and speed were 0.561 and 0.000057, respectively, indicating their influence on scrap rate. Adjusting these parameters within optimal limits is recommended to reduce scrap, particularly from underfilling, uncrowned bottles, and contamination. Implementing these corrective measures is expected to enhance product quality and operational efficiency.