with Arrow Solutions and Rubix UK
Refresco faced challenges with its high-speed carton packaging lines due to an outdated and complex leak detection process. Partnering with Rubix UK and Arrow Solutions, Refresco adopted a bespoke leak detection solution designed to improve safety, streamline operations, and simplify procurement. By integrating a ready-to-use, low-VOC, non-flammable product, the collaboration offered a safer, faster, and more efficient alternative to traditional methods.
Keep reading to discover how this tailored solution transformed operations at Refresco and delivered measurable savings in both time and cost.
For the full case study; download the complete Refresco case study to explore the detailed results, step-by-step implementation, and insights from Arrow Solutions and Rubix UK. See firsthand how a bespoke leak detection solution can enhance safety, efficiency, and operational performance.
Introducing Refresco and Rubix
Refresco is the world’s largest independent bottler of beverages, operating 78 manufacturing sites across the globe, including a major facility in Bridgwater, UK. Ensuring product quality and packaging integrity is critical to maintaining customer satisfaction and brand reputation — especially when working with high-speed carton packaging lines.
Rubix UK, one of Europe’s leading distributors of industrial products and services, approached Arrow Solutions on behalf of Refresco. The challenge: find a safer, simpler, and more efficient alternative to Refresco’s existing leak detection solution.
The challenge
Refresco’s previous leak detection method involved a two-part system: a solvent and a powdered dye that engineers had to manually mix to create the detection fluid. This presented several issues:
Health & safety risks
The product was flammable, had high VOCs, and gave off strong odours — requiring storage in a locked chemical cupboard away from the production line.
Operational inefficiency
Preparing the solution was time-consuming and messy. Operatives were pulled away from production for up to 20 minutes per test.
Supply chain complexity
The two-part system was sourced from different suppliers with long lead times and high minimum order values (MOVs), complicating procurement and stock control.
Additionally, Rubix had not previously supplied this type of product directly to Refresco, making this an opportunity to create brand new business for both Rubix and Arrow Solutions.
“Arrow’s consultative approach really stood out. They took the time to understand our processes and challenges before recommending a solution. The great work Caroline did in coordinating the project made the whole process seamless and ensured we achieved the best possible outcome.”
Simon Marsh, Insite Manager, Refresco Bridgwater
The solution: a bespoke leak detection solution
Arrow’s Technical Team worked closely with Rubix to design a bespoke leak detection solution based on the trusted Lotoxane® platform – a safe, non-flammable, low-VOC solvent. The new formulation integrated both the solvent and dye into a single, ready-to-use product, delivering a host of benefits:
Improved safety
Non-flammable and low in VOCs, the product can be stored near the production line, reducing the need for restricted storage.
Time savings
Eliminated the need for on-site mixing, allowing operatives to focus on their core tasks.
Simplified procurement
One product, one supplier, faster lead times, and no mixing or preparation needed.
The results
Following a successful trial, the new solution was implemented into regular operations at Refresco Bridgwater. The savings were immediate and significant:
>£5K
Annual stock reduction
>£9K
Annual labour savings in time
“Working with Rubix and Arrow has been a game-changer. The new product is safer, easier to use, and has helped us cut down on both time and cost. It’s a great example of what can be achieved through collaboration.”
Production Manager, Refresco Bridgwater
This highlights the power of collaborative innovation. By understanding the customer’s operational pain points and working closely with Rubix, Arrow Solutions delivered an efficient, compliant, and bespoke leak detection alternative that brought measurable benefits to one of the UK’s leading beverage manufacturers.
If you want to keep reading… download the complete Refresco case study. See firsthand how a bespoke leak detection solution can enhance safety, efficiency, and operational performance.
Interested in custom solutions?
When safety matters as much as performance, trust Arrow to deliver.
To learn more about how Arrow can improve your operations, get in touch with our team. For the latest news and updates, you can follow us on LinkedIn.
