About Verallia
Verallia is a global manufacturer of glass packaging, producing bottles and jars for customers across multiple industries.
At its Pescia plant in Italy, Verallia operates complex glass production lines where process anomalies can quickly lead to production losses, equipment damage, fires, and safety risks.
To improve production performance and safety, Verallia looked for a way to detect these issues earlier, respond faster, and give production teams better visibility into what was happening on the line.
The challenge
Glass production at the hot end is fast-moving and complex, with process anomalies requiring immediate attention.
Glass jams, fallen containers, and other deviations can escalate quickly. If they are not detected and addressed early, they can lead to production losses, equipment damage, fires, and safety risks.
Manual observation alone makes it difficult to consistently detect these events early, understand what caused them, and prevent them from recurring.
Verallia needed a solution that could:
- Continuously monitor critical areas of the hot end
- Detect production and safety issues in real time
- Alert operators immediately when intervention is required
- Automatically intervene when high-risk events occur
- Capture incidents and provide data for root cause analysis
The solution
Following an initial pilot on one of its largest production lines, Verallia expanded Cerrion across the entire hot end of its Pescia plant.
Cerrion AI Agents continuously monitor production areas in real time and detect issues such as glass jams and fallen containers as they happen.
When an issue occurs, the system responds immediately:
- Operators receive sound alarms in real time, helping them react faster to developing issues.
- High-risk events trigger automated machine section stops, preventing problems from escalating further.
- Incidents are automatically captured and recorded, giving production teams the context they need to understand what happened.
Incident analytics and anonymized video streams provide fact-based insights, helping teams investigate recurring issues and improve shift, daily, and weekly routines.
“This project is unleashing new ways of working at the hot end, enabling fact based discussions through shift, day and week routines and allowing hazard reduction for our teams, thanks to reduced magnitude and frequency of anomalies.”
Vincenzo Onesti Director of Operational Excellence, Verallia
Impact and outcomes
- Up to 50% faster response times
- Entire hot end covered following the initial pilot
- Automated closed-loop response through alarms and machine section stops
- Improved visibility into recurring production and safety issues
From pilot to rollout
Verallia initially deployed Cerrion on one of its largest production lines at the Pescia plant.
The pilot showed that Cerrion could help teams detect anomalies earlier, react faster, and reduce the magnitude and frequency of production and safety issues.
Based on these results, Verallia expanded Cerrion across the entire hot end of the Pescia plant, bringing real-time detection, automated intervention, and incident analytics across a broader part of its production operations.
