What’s Slowing Down Your Brewery? A Smarter Way to Fix Labor Bottlenecks

The U.S. beer market is estimated to grow at an average of 2.46% over the next five years. To keep up, many breweries are looking to scale — but it’s not always easy.

One of the biggest bottlenecks for breweries today is labor optimization. Staffing shortages and manual processes can make growth feel more like a grind than a win.

The good news? You don’t need a complete staffing overhaul to see big results. Strategic upgrades — particularly to your can handle application process — can deliver lasting gains. It starts with pinpointing what’s slowing you down, then choosing the most efficient, cost-effective way forward.

If bottlenecks are limiting your output, this blog is for you. We’ll cover how to boost efficiency without adding headcount, including common production slowdowns, practical ways to streamline your line and smart tech that keeps downtime to a minimum.

Common Labor Bottlenecks on the Packaging Line

For a growing brewery, speed and efficiency hinge heavily on how you use your people. Some of the most common bottlenecks in this arena include:

• Manual can carrier application slowing production: The filler usually sets the pace for a canning line, but it often runs faster than manual handle applicators can keep up. Manual work also increases the risk of errors, disrupting line flow and wasting time.

• Time-consuming changeovers between can sizes or pack types: For small and mid-size brewers who don’t run every day, changeovers eat into valuable production time when the line is active.

• Downtime caused by outdated or high-maintenance equipment: Older machinery demands more operator attention and can fail unexpectedly, halting production and wasting valuable labor hours.

• Over-reliance on multiple operators for repetitive tasks: Relying on multiple operators for repetitive packaging tasks can tie up valuable team members on lower-impact work. By freeing them from routine, manual processes, you allow your team to focus on higher-value tasks.

Each of these bottlenecks can limit your brewery’s ability to meet demand, leaving valuable revenue on the table. But the takeaway is clear: Simplifying with automation is essential for breweries that want to grow.

While there are multiple ways to resolve packaging bottlenecks, adopting smart, targeted automation remains one of the most efficient paths forward.

Smarter Packaging Solutions That Boost Efficiency

While manual can carrier application can work, it often slows down production, increases errors and ties up valuable labor. Switching from manual processes to automated application not only speeds up your line but also reduces downtime and frees your team for higher-value work, without disrupting your existing setup.

Here are four key features to look for in automated canning line equipment:

• Versatility: Handles multiple can sizes and pack types for greater flexibility.

• Compact Footprint: Fits into tight spaces without requiring major layout changes.

• Simple, Tool-Free Adjustments: Allows quick changeovers so your team can keep production flowing smoothly.

• Built-In Automation: Cuts labor needs by taking over repetitive tasks while maintaining speed and quality.

Some automated multipack applicators can reduce the number of operators needed from two to one by handling carrier loading, application and tray packing all in one step. The VPA-80 from Roberts PolyPro is a prime example of how automation transforms manual processes into streamlined, efficient workflows.

The Power of a Thoughtful, Cost-Effective Upgrade

The VPA-80 is designed to overcome the inefficiencies of manual can packaging while meeting the key needs of growing brands. When paired with Craft-Pak® Versa, it offers numerous benefits, including a potential return on investment (ROI) in as little as 12 months.

With speeds up to 80 cans per minute (CPM), the VPA-80 often outperforms typical machines and can also boost lines currently running at manual application speeds of 50 to 60 CPM.

Changeovers are faster and easier since no changeparts are required between 4- and 6-packs. Simple height adjustments for can sizes — including 12, 16 and 19.2 ounces — add flexibility without disrupting your workflow.

Plus, the VPA-80 needs just one operator, reducing labor demands, minimizing errors and keeping your packaging line running efficiently.

Small Change, Big Impact

With an investment starting around $11,500, the VPA-80 offers an accessible entry point to cost-effective automation. It’s designed to deliver high ROI for both small and mid-sized breweries, helping brands meet demand without complicating workflows.

Wondering if the VPA-80 is the right fit for your brewery? Start by assessing your current line for easy efficiency wins, then explore how automated carrier application can help you succeed.

Remember: You don’t need a full overhaul to see major benefits. Sometimes, one smart upgrade is all it takes.

Learn more about the VPA-80 from Roberts PolyPro and discover what it can do for your operation.