Case of success: Beginning of filling production line for multiformat containers
Case of success: Beginning of bottles filling production line for a complete filling, capping and labelling facility for glass, can and plastic containers.
Multinational company of the food solid sector: ingredients and flavourings, specialists in herbs, aromatic spices and condiments for the catering sector, has built a new factory in the United Kingdom in which they have installed two bottle packaging lines for filling, labelling and packing their products.
The client needed to handle containers at the beginning of the line made of different materials in a single line.
At the first stage implies handling a total amount of six containers: three glass containers, two plastic containers and one can, very different both in size and geometry and at a constant production rate of 170 containers per minute.The project consisted in depalletizing squared cans and round glass jars, unscrambling plastic containers, and, moreover, cross all these formats through a rinser machine for cleaning inside the containers before filling.
The client was searching for a turn-in-key solution which allowed them to handle all their containers with different shapes and materials in a single line, and which dimensions allowed for the maximum space utilization in factory.
Three machines connected at the beginning of a filling line
Traktech is responsible, in this project, for the machines at the beginning of the line. Contributing with a compact line of three connected machines.
The solution consists of a depalletizer, an unscrambler and a rinser to handle can, glass and plastic containers, which require differentiated handling before the beginning of the packaging line.
2D layout of the beginning of the empty bottles filling line.
DPI depalletizer for glass and can containers
An empty containers depalletizing system is the first machine of these containers filling line.
It consists of three stations:
- Preload of full pallets of empty containers.
- Pallets elevator.
- Empty pallets storage and cardboard divider layers.
Can and glass containers are pushed to an “inliner” conveyor which places them in line to transport them towards the Rinser model SG-20, through a side grip lowering device to go from 2300mm height, to the working height of 1000mm and that go through the unscrambler.
This depalletizing system, designed specially to satisfy the needs of this condiments and additives company, is only one of the diverse depalletizer versions that we offer to unscramble containers in filling lines.
From simple depalletizers to more complex and automatic systems, which can add more benefits. Additional information in Glass, plastic or can bottles depalletizers.
Rotrak AAF unscrambler with automatic format change for plastic containers
The Rotary Unscrambler Rotrak AAF (Automatic Adjustable Funnel), sorts and positions bottles standing in the line.
Bottles come into the unscrambling machine through a bulk elevator/conveyor of 1500 li capacity. In the upper disc, bottles are previously placed in tangential position inside the drawers.
Through the positioning detection by vision camera, the position of each container in each drawer is analysed and a signal is sent to the funnels so that the pneumatic cylinder rotates the container allowing it to be placed in the correct position, standing.
Regarding format change, pressing a button of the machine touchscreen, all the mobile parts of the pre-orienter and the funnels will move adapting to each preestablished format in the PLC memory.
With this system, up to 20 different formats could be programmed and the format change takes between 1’ and 2’, corresponding to the time spent changing the program in the touchscreen and loading the machine.
Furthermore, this containers unscrambler fulfils with three fundamental premises: it is a compact equipment, versatile and energetically efficient, aspects that impact in the profitability of production firms.
Rinser model SG-20 with ionized air for cleaning all the containers
The rinser is the machine in charge of cleaning inside the containers from any foreign body, residual element, dust, etc., which could be inside them before their arrival to the filling machine.
Through a rotary system of 180 degrees, containers pass by the blowing zone with filtered and ionized compressed air with vacuum towards filter G4-F8 – EN779 of the smallest particles and a collector drawer for the big particles for a posterior quality analysis.
Scheme of the empty containers cleaning system by ionized air.
Once the empty bottles are clean, they are returned to their original position and delivered to the following filling stage.
There are three different types of “Side-Grip” rinsers which are chosen in terms of container geometry, material, and production rate.
Regarding the cleaning system, for this specific case we have chosen the cleaning system by bowing with ionized/filtered compressed air, but we also have two additional cleaning systems:
- Basic blowing with filtered compressed air and particles collector drawer.
- IonRinseTM blowing with constant ionized air and particles vacuum through Ionrinse™ without using compressed air. System that allows for thin dust cleaning and it is energetically efficient.
A global vision of the beginning of the line
In the following video, we can see the beginning of this containers filling line from the entrance of the can and glass containers, going through the plastic bottles unscrambling and ending up in the bottles cleaning machine.
Video on our YouTube channel. Follow us!
Optimization of the solution for filling empty containers
This complete machinery for the beginning of the bottles filling line designed and manufactured by Traktech satisfied the specific needs of the packaging line, while adding:
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- Productivity:
Minimum time of production line stop during format changes in the depalletizer, as well as in the unscrambler and rinser.
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- Reduction of the occupied space:
It is a compact equipment. Minimum space used in factory.
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- Flexibility:
New formats can be added to the program telematically, both to the depalletizer and the unscrambler without the intervention of a technician in the factory.
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- Simplicity of use:
Two electrical panels to coordinate the whole line.
Once again, the technical and R&D team in Traktech prove with facts their know-how and experience through a project which has been taken since the beginning with the maximum rigour and professionality.
For more information, doubts or inquiries about this or any other project, you can contact us through our web form. We will be excited to undertake new challenges!
