Retrospective series:
Engineering a Revolution in Wine Packaging - Hydra Consulting and the Creation of Line 6
When Australian Vintage Limited (AVL) sought to transform their bottling facility into a world-class operation, they turned to Hydra Consulting. This project wasn’t just about modernising equipment or expanding capacity; it was about fundamentally rethinking what a wine packaging facility could achieve.
Hydra Consulting brought a wealth of experience and vision to the table, leading the redesign and implementation of AVL’s Line 6. The result was a state-of-the-art facility that overcame demanding constraints, incorporated cutting-edge technology, and set new standards for efficiency, sustainability, and quality in the wine industry.
Here’s how we made it happen.
The Mission: Transforming a Legacy
The Merbein bottling facility in Victoria, Australia, has a long history. Established in 1914, the site had seen innovation throughout the decades but had not undergone a significant transformation since 2006. With surging demand for its globally recognised wine brands, AVL needed a bottling system that could handle larger production volumes, integrate sparkling wine production in-house, and meet modern quality and efficiency benchmarks.
Hydra Consulting was brought in to design and manage the project from start to finish. Our task? To create a flexible, advanced packaging line capable of delivering unmatched productivity and quality, while navigating complex site constraints.
“This was a forward looking project with world leading efficiency, best-practice implementation supported by a great team across four businesses” Ron van Buuren, Managing Director Hydra Consulting
Meeting the Challenges, One Solution at a Time
Taking on a project of this scale required facing multiple engineering and operational hurdles. But at Hydra Consulting, we thrive on solving challenges that others might shy away from.
1. The Challenge of Space
The Merbein facility presented significant logistical issues. It lacked the space to accommodate a conventional bottling line within a single building. Early designs revealed that the equipment needed for Line 6 wouldn’t fit.
Our solution was to think creatively about the use of space. By cleverly extending the bottling line across three existing buildings, we preserved site operations while enhancing efficiency. We designed custom-built tunnels, conveyors, and lifts that seamlessly connected the spaces. Each element was configured to maintain safety, efficiency, and compliance with rigorous industry standards.
2. Integrating Cutting-Edge Technology
To meet AVL’s requirements for future-proof innovation, Hydra Consulting led the integration of advanced machinery and control systems. We didn’t just select the best equipment—we ensured every component worked harmoniously as part of a unified system.
Key features included:
Industry 4.0-enabled digital twinning and real-time data capture for predictive maintenance and operational insights.
A centralised control system, providing operators visibility over the entire facility and enabling seamless adjustments on the fly.
Advanced quality assurance technology, including visual inspections and label positioning checks, which set Line 6 apart as a leader in precision.
3. Energy Efficiency and Sustainability
We understood the importance AVL placed on sustainability. To address the challenges of regional power variability and minimise the facility's environmental footprint, we ensured energy efficiency was at the forefront of every design choice.
From using energy-efficient motor drives to developing systems that could safely restart without losing production data during power outages, we created a line that combined reliability with reduced energy consumption. AVL’s commitment to renewable energy, symbolised by signing a corporate power purchase agreement, was fully supported by the designs.
Collaboration That Sets a Benchmark
One of the defining features of this project was the incredible collaboration between Hydra Consulting and key partners Foodmach and Costa Enterprises. While Hydra Consulting served as the leadership and design backbone of the project, our teamwork with these industry experts ensured outstanding outcomes.
Foodmach delivered exceptional integration work, designing equipment such as depalletisers, palletising systems, and conveyors to meet the unique requirements of the space.
Costa Enterprises provided state-of-the-art European machinery, ensuring robust performance and high-quality output.
Together, we created a unified vision and tackled the project’s complexities with precision and creativity.
Innovations That Deliver Results
The success of Line 6 isn’t just visible in its engineering; it’s reflected in the system’s results and impact.
1. Unmatched Production Capabilities
Line 6 enabled AVL to bring sparkling wine production in-house, achieving rates of 12,000 bottles per hour for still wine and 7,500 bottles per hour for sparkling wine. These speeds represent some of the fastest in the Australian market and significantly improve AVL’s competitiveness.
2. Raising the Bar on Quality
The inclusion of world-class QA systems ensures every bottle leaving the Merbein site meets the highest quality standards. Features like precision seam orientation for labeling and control over carbonation ensure a consistent and premium product.
3. Sustainability as a Core Value
Line 6 is more than efficient; it’s a model of sustainable engineering. By reducing energy use and incorporating renewable energy strategies, it stands as proof that high performance and sustainability can go hand in hand.
Lessons Learned
Reflecting on this project, a few key lessons stand out as pivotal for achieving success in large-scale transformations like Line 6:
Constraints Are Opportunities for Creativity. The spatial limitations of Merbein forced us out of conventional thinking and led to breakthroughs in adaptive design and unique solutions.
Collaboration Supercharges Innovation. Bringing together the expertise of Hydra Consulting, Foodmach, and Costa Enterprises allowed us to create something greater than the sum of our parts.
Future-Readiness Is the New Standard. Building systems that can adapt to future needs, with modular designs and cutting-edge digital integration, ensures long-term value for clients and their customers.
A Milestone Achievement
At Hydra Consulting, we take pride in every project, but Line 6 stands out as a landmark moment. It’s a testament to what’s possible when visionary goals meet expert execution.
Today, the Merbein facility doesn’t just represent AVL’s success; it symbolises the impact that design-led innovation and strategic collaboration can have on an entire industry. We’re honored to have played a leading role in this transformation, and we look forward to applying the lessons of Line 6 to future projects.