What happens when a prestigious brand, official supplier to the Dutch Royal House, decides to revolutionize its production line in a space that is both extremely limited and strategically vital? A complex challenge emerges – made of millimetric fits, smart automation, and out-of-the-box thinking.
Enter Clevertech: Italian excellence and partner of the Smart Packaging Hub, able to turn complex needs into tangible solutions.
«De Kuyper wasn’t looking for a supplier – they were looking for a partner who could see beyond the technical drawing. Someone able to turn a logistical constraint into a lever for efficiency. We’re proud of how we responded to this challenge» says Luca Carollo, Regional Sales Manager at Clevertech.
A site full of history – and constraints
We’re in Rotterdam, along the historic canal that houses De Kuyper’s most iconic facility, the oldest distillery in the Netherlands. Here, copper stills heated with wood can still be admired – symbols of a heritage with deep roots.
It is here that a truly unique and ambitious project takes shape: the design of a beginning- and end-of-line system to handle glass bottles used for premium spirits. But two seemingly incompatible constraints loom large: limited space and high fragility of the content.
«The distillery is set in a fascinating historical context, but every square meter comes at a high cost. We knew from the start this wouldn’t be a standard project» continues Carollo. «We had to rethink how industrial space is viewed and persuade the client to look at the plant with new eyes».
The spirits journey: a valuable contribution
For Clevertech, the project marks a strategic milestone in the spirits sector – a segment that, until three years ago, represented only a marginal share of global orders, but is now gaining strategic relevance within the company.
The first collaboration with De Kuyper was born from a highly customized request, with three key objectives at end-of-line: preventing glass bottle breakage (12,000 per hour), enabling extremely fast format changes, and optimizing the limited available space.
«Our job is to turn exceptions into method. Constraints push us to be creative. In this case, the biggest challenge was fitting everything into a few meters without sacrificing performance or quality» explains Carollo.
Custom solutions, centimeter by centimeter
The technical response required tailor-made solutions – literally designed to the centimeter. Clevertech developed a twin-lane product pick-up table for its case packer, reducing the linear speed of the conveyor by 50% compared to the previous setup, thus minimizing bottle impact and lowering the risk of breakage.
The depalletizer was programmed to interact in real time with the filler, automatically anticipating the product change cycle. The result? A format change completed in just three minutes – well below the contractual target.
«When we presented the initial drawings, the challenge seemed to push the limits of feasibility. But once the system was installed and the machine integration tested, the client could see the efficiency of the solution first-hand. All technical specs were met – with improvements that exceeded expectations, in record time».
Reducing linear speed and reconfiguring the table significantly decreased bottle breakage, creating real economic impact.
«We estimated a significant drop in damaged bottles compared to the previous setup» notes Carollo. «In numbers, this means substantial savings – not only in raw materials, but also in transportation costs and environmental impact. A lighter, more sustainable logistics chain, spread across 72,000 bottles a day».
Rethinking space: from surface to volume
It’s not just about performance – it’s about perspective. Clevertech proposed a shift in mindset: from surface to volume. Where others saw a limited-floor facility, the company saw a three-dimensional space to be optimized with vertical, modular, and intelligent solutions.
«In the Netherlands, space is gold. We designed many vertical solutions, using every centimeter» Carollo emphasizes. «Many manufacturers think horizontally. Here, we thought vertically. And I must say, we Italians are particularly inspired when it comes to thinking outside the standard».
A bold move into the spirits sector
Final testing is scheduled for late June, but initial trials have already left the client highly satisfied with what they saw at Clevertech. The result opens new prospects: De Kuyper has launched a full-scale renovation plan for the factory, set to last several years, with the goal of doubling volumes and expanding the product range. With this first project, Clevertech positions itself as a strategic partner for the entire journey.
«We’re just at the beginning» Carollo explains. «We’ve already presented solutions for logistics and for the future evolution of De Kuyper’s entire production. And we kept insisting on thinking in terms of volume, not just surface. De Kuyper has proven very receptive to our ideas, and we’ve found a true excellence-based partnership – both in communication and mutual listening».
Beyond the project: the culture of well-done work
The newly developed system will be officially unveiled during the Clevertech Day, on June 5, 2025, at Clevertech headquarters, where clients from the spirits industry will be invited. Right there – under the office balcony – will stand the symbolic gateway to a market full of innovation, growth, and opportunity. And a living example of what can happen when technology, vision, and passion meet.
After all, the difference between a good job and a well-done one lies in the ability to listen, design, and improve. In this project, the collaboration between Clevertech’s R&D and programming departments – two of the company’s proudest assets – led to advanced, fast, and integrated solutions. A concrete example of internal synergy that translates into value for the client.
Pushing past expectations and limits – even spatial ones – and leaving behind more than a project: a shared future built on innovation, trust, and enduring solutions.