Case Study: Pepsi-Cola Bottling Co. achieves 50% faster changeovers and under-1-year payback with Wonderware

Built In 2002, PBV Garner Has Grown From Producing and Distributing 189 Different Products to Over 500 Today

Pepsi Bottling Ventures (PBV) of Idaho, a manufacturer and distributor of more than 100 flavors and brands, faced operational challenges at its Nampa plant: a mix of new and legacy equipment, manual and incomplete downtime tracking, long and inconsistent changeovers, and a lean engineering staff that made data-driven decision-making and ROI justification difficult.

PBV deployed Wonderware System Platform, MES Performance, InTouch HMI and Historian to capture real-time PLC data, standardize reporting and pinpoint root causes. The software revealed a filler-line bottleneck, cutting changeover time by about 50%, boosting line efficiency ~10%, reducing material and packaging waste, and delivering payback in under one year with annualized savings of more than $78,500—while enabling faster, more consistent cross-functional decisions and easier system replication.

Pepsi-Cola Bottling Co.

Scott Jamison

Pepsi-Cola Bottling Co.