In the world of spirits, some production sites speak for themselves. Certain plants, by virtue of their history and strategic importance, serve as true landmarks in the global alcoholic beverage industry.
In one such emblematic site, a highly complex technical and logistical challenge emerged: the installation of a new glass line for gin and spirits at 350 bpm, within a production facility dating back to the 1980s. A project that required far more than a technical upgrade.
“We knew”, says Paolo Soliani, Regional Sales Manager at Clevertech, “that every decision in this context would carry symbolic weight as well as operational impact. It was a chance to demonstrate our expertise and holistic vision in high-end line integration – offering solutions that go beyond the stated request”.
The challenge was taken up by Clevertech, an Italian system integrator with a strong international focus and an operational branch in the UK, led by General Manager Matthew Carey. A partner that doesn’t merely execute, but builds solutions with a forward-looking mindset.
Customer needs: layout, performance, vision
The customer required a high-speed glass line at 350 bottles per minute, to be installed in an established industrial setting. The 1980s facility was well-structured but space-constrained, with intricate access points and a broad range of formats to manage – both in terms of size and fragility. Adding to the complexity was the need to minimize manual handling and optimize internal logistics.
“The biggest challenge”, Soliani explains, “was not just bringing new machines into a tight space. It was designing a system that could bridge past and future – one that would integrate with the existing infrastructure without disrupting it, while radically improving it”.
The goal was not only to support day-to-day production but to create a layout capable of accommodating future expansions, additional lines, and new process flows. Clevertech responded with a modular, flexible, and scalable solution tailored to the site.
The core of the proposal: modularity and vision
The project was built around two main blocks: depalletizing and end-of-line operations. At the line’s start, Clevertech delivered a complete robotic depalletizing system, including the removal and handling of all packaging materials – such as layer pads – via an anthropomorphic robot arm with precise gripping control through a vision system.
Auxiliary packaging materials are moved via an overhead conveyor system, freeing up valuable floor space and delivering materials directly to an external compactor. This solution not only boosts efficiency but also improves hygiene and cleanliness by reducing dust and minimizing interference with personnel.
“We approached it modularly, not just in terms of individual machines”, says Soliani. “This allowed us to anticipate the customer’s future needs, designing a system that can evolve without having to be dismantled or rethought”.
On the output side, the line features a palletizing system with robotic layer formation, centralized pallet and slip-sheet feeding via shuttles, and connection to a high-speed pallet wrapper – optimizing logistics and laying the groundwork for future integration with additional lines and AGV systems (Automated Guided Vehicles) that can safely and autonomously transport materials within the plant.
Beyond expectations: the value of anticipation
What made this project unique was not only the technical precision but also Clevertech’s ability to look beyond the customer’s stated needs. From the outset, Clevertech proposed solutions designed for a future-ready layout – capable of being expanded, integrated, and reconfigured to align with the customer’s long-term vision.
“The client asked us to solve a current problem, but we brought them a piece of the future”, says Soliani. “Not only through modular infrastructure, but with a design logic focused on integration and growth. Today, the system is ready to host new lines, connect to additional shuttles, and integrate with the factory’s smart logic”.
Clevertech’s approach is not just engineering-driven – it is strategic. This mindset helped establish a relationship based on trust and a shared vision for industrial evolution.
An international team effort
The project’s success is the result of close collaboration between Clevertech’s Italian headquarters and its UK branch. The UK team, led by Matthew Carey, played a vital role – not only in maintaining the client relationship and gathering precise technical requirements, but also in overseeing on-site operations and managing installation and commissioning, thanks to the expertise of the local team.
“The UK team was essential”, Soliani emphasizes. “Without them, we couldn’t have built such a strong and constructive partnership. The teamwork between our Italian HQ and the UK branch was a true example of synergy – based on listening, responsiveness, and shared goals”.
Clevertech’s internal organization, offering a single point of contact for the entire project, allowed the customer to interact with a streamlined structure, capable of coordinating suppliers, integrators, and installers without dispersion – an added value that often makes the difference.
Tangible impact and future outlook
The benefits for the customer go beyond efficiency: the new layout improves safety and sustainability by minimizing manual handling and forklift usage – reducing emissions and improving operator protection. Overhead material transport improves general cleanliness and minimizes contamination risks.
“Reducing low-value-added tasks means enhancing human capital and creating a safer, more sustainable production environment”, notes Soliani. “Our mission isn’t just automation: it’s improving the overall quality of work”.
The project was in progress during 2025, with final testing by the end of the year and operational launch in spring 2026. Yet discussions are already underway about next phases; proof that mutual trust is growing into a long-term partnership.
Vision, flexibility, listening
Having vision means anticipating needs before they’re voiced – offering solutions that not only solve problems but prevent future ones, opening space for opportunity.
“Understanding unspoken needs is what turns a machine into a strategic asset”, concludes Soliani. “Our job doesn’t end with delivery: it starts there. Every system is a seed, and we build the fertile ground for it to grow over time”.