Automated, Integrated Packaging Systems
Mark Anthony Brewing
Mark Anthony Brewing
Mark Anthony Brewing’s facility in Columbia, South Carolina, is the largest and most technologically advanced brewery built in the U.S. in the past 28 years. This 1.2 million-square-foot highly automated facility produces 80 million cases per year.
Normally, a project of this size would take years to plan and build. MAB’s ambitious timeline saw the site transform from initial groundbreak to production of the first saleable case of product in just 346 days. Our integrated design-build team was able to meet the speed and high build quality experience needed for the challenging project.
The facility has the capacity to produce 6 million barrels of finished product and package 80 million cases per year, with a packaging speed of almost 1,000 barrels per hour.
With an integrated packaging system, state-of-the-art processing, and a highly automated process in place, Mark Anthony Brewery’s South Carolina facility is well positioned to continue its pioneering new beverage categories and creating inspirational beverage brands.
The bottle filling lines run 50,000 bottles an hour, and the variety pack line that includes different flavors of Mark Anthony’s products.
Cans enter the warehouse on a pallet with no lid ends. The automated warehouse system brings the product based on a call from the control system. The facility contains automated tunnels to the warehouse, where the system brings the product to the packaging area as required. The automated warehouse takes finished goods away based on whether it’s a single-flavor product or a product for a variety pack system with multi-flavors.
These packaging lines are mirrored but operate in a combined manner, so plant floor operators can move and access the lines. Both lines are capable of running 120,000 cans an hour. It’s a huge capacity, and it’s very unique.
One of the main sustainable aspects of the plant is its goal of eliminating emissions instead of buying CO2. The facility aims to be 100% self-sufficient by collecting the CO2 that’s produced during fermentation, storing it, and then reusing it at the end of the process to carbonate the product.
Despite a myriad of challenges that threatened both schedule and budget, Clayco pulled together its in-house teams from Lamar Johnson Collaborative and Clayco Engineering Services to prioritize what designs needed to happen. The “speed to market” during the early phases of Mark Anthony Brewing’s new facility was truly unprecedented. Without design-build, it’s doubtful the project team would have pulled off such an aggressive schedule.