Pokka Pte Ltd (Singapore)

Pre-Installation Challenges

High Non-Productive Time from Frequent Changeovers, Unstable Operating Rates, and Data Management Limits

Due to the unique characteristics of the Singapore market, high-mix, low-volume production requiring frequent changeovers of various liquid types and bottle formats was essential rather than mass-producing a single item. However, conventional lines required long hours for changeovers, resulting in extended non-productive time and forcing the plant to hold higher product inventory, which posed significant challenges to production efficiency. Furthermore, frequent line disruptions led to operational stoppages that depressed operating rates, while inadequate monitoring functions made it difficult to manage critical details such as filling volumes and bottle capping torque data.

Key Deciding Factors

Flexible Aseptic Changeovers and Seamless Technical Support with Japan

The solution to overcoming these challenges was Shibuya Corporation’s aseptic filling line, which enables liquid and format changeovers while maintaining a continuous aseptic environment. In addition to its high flexibility tailored to the market's demands, Shibuya’s system earned strong recognition for its superior equipment stability (operating rate), stringent sterility, and safety. Furthermore, the rapid troubleshooting support enabled by minimal time zone differences with Japan, alongside Shibuya’s extensive track record and reputation for after-sales service in Japan, served as decisive factors.

Implementation Benefits

Dramatic Reduction in Non-Productive Time and Accelerated New Product Launches

Following the installation, smooth changeovers performed under aseptic conditions drastically reduced non-productive downtime. The plant established an agile production framework capable of accommodating more than 20 to 30 liquid and bottle format changeovers per month. This flexibility made new product test runs and trials significantly easier, directly enhancing Pokka’s competitive edge in the market.

Future Outlook

Pursuing Greater Versatility and Horizontal Expansion Across Global Facilities

Building on the proven production flexibility and high operational stability achieved at the Singapore plant, Pokka is currently considering next-generation lines suitable for large-scale production, aiming for horizontal deployment to other overseas factories. Furthermore, looking toward the adoption of even more versatile advanced equipment—such as dual-cap compatibility for 28mm and 38mm diameters, as well as aseptic filling for carbonated beverages—Pokka continues to pursue manufacturing innovation in close collaboration with Shibuya Corporation.

Product Images: Pokka Pte Ltd (Singapore)

Pokka Pte Ltd (Singapore)