CASE STUDY | FOOD & BEVERAGE

Emulate3D Brings Garvey’s Bottling Improvements to Life

Glenvern Group uses Emulate3D® by Rockwell Automation to visually showcase the throughput and efficiency benefits of Garvey’s bottle accumulation systems

Garvey’s patented accumulation tables and accumulation conveyors can handle the most unstable products at the highest rates in the industry. They also provide the lowest total cost of ownership, with payback periods counted in months, not years. Garvey's mission is to maximize your production!

Garvey Conveyors

Challenge

Finding a solution that could run on standard hardware and be easily manipulated during live demonstrations to potential customers.
Need to be able to change inputs and show different scenarios in real time.

Solution

Emulate3D®

Result

Through Emulate3D visualisation, Garvey was better able to demonstrate the benefits of its accumulation systems to key beverage customers.
Screen-recorded demos, combined with live interaction, enabled sales team to visually communicate critical production line insights, supporting customer acquisition efforts.

Conveyor and accumulation system specialist, Garvey by Columbus McKinnon (Garvey) was seeking to better showcase the throughput and efficiency benefits of its bottle accumulation systems.

Garvey products serve customers ranging from small breweries to the world’s largest manufacturers of food, beverages, pharmaceuticals, and household products.

An accumulation table is a specialised type of conveyor system designed to temporarily hold and accumulate products or materials. These tables can be circular, rectangular, or even custom-shaped to fit specific production line requirements. They serve as a buffer zone in the production process, allowing for the smooth flow of items between different stages of manufacturing, filling, labelling, or packaging.

Through relationships with its parent company, Columbus McKinnon, Garvey discovered digital twin visualisation software Emulate3D, by Rockwell Automation. Columbus McKinnon had previously engaged Australian company Glenvern Group, a Rockwell Partner, to visualise manufacturing projects and Garvey saw the potential of using Glenvern Group’s specialist Emulate3D application team to sell the benefits of its solutions globally.

“We could see that using 3D visualisation software that kept track of key data points and simulated real world conditions could better showcase the benefits of our accumulation systems,” said Bill Reese, senior director, engineering, Garvey.

“Glenvern Group had customised the Emulate3D software for another Columbus McKinnon company, Dorner, and we could see that it’s one of the most sophisticated yet intuitive 3D visualisation technologies out there. We saw the potential to help showcase benefits to potential beverage customers, and improve our customer acquisition efforts,” Reese said.

*Garvey’s accumulation system in action*

Challenge

Garvey’s goal was to visually demonstrate how adding accumulation systems can reduce bottlenecks and improve throughput in a bottling production line.

“The challenge for us was finding a solution that could run on standard hardware and be easily manipulated during live demonstrations to potential customers. We didn’t have an internal solution, so Rockwell’s Emulate3D was ideal,” said Reese.

“It’s one thing to show a simulation that’s been created in advance, but being able to change inputs and show different scenarios in real time has been a game changer,” Reese said.

Solution

Emulate3D, by Rockwell Automation, is an industry-leading software that provides a dynamic 3D modelling environment for creating high-fidelity physics-based models of discrete manufacturing and material handling systems.

“Glenvern Group has been specialising in Emulate3D (and its previous software versions) customisation and implementation for more than 20 years. It combines visualisation with simulation, virtual commissioning, and digital twin functionality,” said Alec Poulton, director, Glenvern Group.

“Having worked with other Columbus McKinnon companies across several different offices in the Asia-Pacific and North America, it was an exciting opportunity to work with Garvey in the U.S. We set up a full visualisation of a bottling plant that ideally showcased how accumulation systems can reduce bottlenecks and keep production flowing,” he said.

Garvey used Rockwell’s Emulate3D software and Glenvern Group’s expertise to accurately model its accumulation systems and display their benefits, backed by data, to potential customers. (Note: the simulation above shows the same bottling production line pictured earlier in the article.)

“Essentially, without an accumulation table, if one part of production stops, it all stops. With accumulation tables, you have an amount of buffer where production can continue in parts, while issues are fixed. It can also highlight optimum times for preventative maintenance, where it has the least impact on throughput,” he added.

Emulate3D is used globally by an extensive range of industry sectors, including automation and materials handling, robotics, diverse manufacturing processes, logistics and warehousing, OEM and machine builders, airports, and baggage handling.

Result

Through Emulate3D visualisation, Garvey was better able to demonstrate the benefits of its accumulation systems to key beverage customers.

“Screen-recorded demos, combined with live interaction, enabled our sales team to visually communicate critical production line insights, supporting customer acquisition efforts,” said Reese.

“The clear visual examples contained important data such as bottles packed, cases packed, including number packed per minute in the last 60 seconds and overall. We could use this data in a before and after demonstration to highlight the benefits of our accumulation systems,” he added.

Columbus McKinnon now uses Emulate3D across multiple locations and companies, including Garvey and Dorner. In addition to supplying the software, Glenvern Group provided training, customisation, project guidance, and ongoing technical support, so that users can optimise the value they receive from Emulate3D.

Garvey helps companies overcome complex production challenges, so having a clear, professional visual demonstration of how this is achieved – backed by data – is helping to grow sales efforts.

“Rockwell’s Emulate3D software is a game changer for us, and Glenvern Group is highly experienced in how to make the most of it. We’ve enjoyed the collaboration and found Glenvern to be highly responsive with excellent communication throughout the project,” said Reese.

“Our sales team feels enthusiastic to take this to meetings. We always knew we could deliver for our customers, but being able to show this in such an effective way takes things to a new level,” Reese concluded.

Published April 28, 2025