PD_Packaging Digest

Packaging Digest, April 2013

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24 BEST PRACTICES // APRIL 2013 www.PackagingDigest.com hopper on a cleated conveyor. Te 24-pocket unscrambler has two bowls that rotate in different directions to achieve proper bottle orientation. Te bottles leaving the unscrambler are conveyed on a vacuum conveyor to eliminate tipping. "A major reason that we selected the Posimat unscrambler is because the changeover from one bottle to another is so quick. Once the new bottle is programmed, it takes a push of the button on the HMI and toolless changeover of the orienter in minutes to perform the changeover," says Sonderman. Te bottles travel to a Pago Model 520 non- stop pressure-sensitive labeler that applies both front and back labels as well as wraparound labels. Sonderman says, "We label before filling, because there is less product waste if we have to discard a bottle because of a bad label." Te Model 520 labeler was sold to Aerofil by DTM Packaging LLC, but American Fuji Seal Inc. has since purchased Pago. DTM is still the distributor for the labeler in the U.S. Te labeler features four complete label stations arranged for non-stop configuration to apply the front and back labels. When a roll of labels runs out, the system automatically switches label stations on the same side of the machine, allowing production to continue uninterrupted during label roll changes. Te operator slides out the label head requiring a new label roll, makes the change and then slides the head back into position, ready to operate. Sensors detect the bottles entering the machine and adjust the speed automatically. A wheel and chain alignment system separates and aligns the bottles for optimum positioning without the need for changeparts. An upper bottle hold-down belt holds the bottles in place during the labeling process. Tis belt is equipped with an adjustable air bladder that compensates for slight differences in bottle height. Te main conveyor and holddown belt are all servo driven and change speeds "We label before filling, because there is less product waste if we have to discard a bottle because of a bad label." — Joe Sonderman, ATI's svp of ops The pressure-sensitive labeler features four complete label stations arranged to apply front and back labels without stopping for label changes. The versatile case packer efficiently handles glass, plastic, cans and paperboard in both round and non-round configurations with containers of various sizes. It also handles a variety of secondary packaging container formats, including RSC cases, trays and display trays magenta cyan yellow black synchronously with the label applicators when the line speed is varied or when changing from one bottle to another. Te labeler achieves a label placement accuracy of +/-2mm. A Cognex camera inspects bottles as they exit to ensure proper label application. If an improperly labeled bottle is detected, it is ejected by an air blast. If three bad bottles in a row are detected, the machine shuts down and triggers an alarm. Mono-block filler/capper From the labeler, the bottles are conveyed to a Pneumatic Scale Angelus (PSA) mono-block filler/ capper that includes a 30-head mass flow filler and a 12-head capper. Te filler incorporates Coriolis technology from Micro Motion USA that achieves +/-1g fill accuracy. To meet ATI's explosion-proof requirement, the mono-block system is rated as intrinsically safe. Product from the blending tanks in the adjacent processing area is pumped to the hold tank installed next to the filler. Level and pressure control in the hold tank maintains a constant level in the tank to maximize fill accuracy. Te product is then pumped to the 30 fill heads, each of which has its own supply tube, enabling each meter to act independently. Te nozzles are designed for laminar flow to minimize splashing and aeration. Each nozzle is equipped with a diaphragm valve that features soft stop/start capabilities that allow the flow profile into the bottle to be adjusted to accommodate difficult items, such as foamy or high- or-low viscosity products. Te Micro Motion system automatically tracks product viscosity and temperature and will sound an alarm if they are out of spec. Te system, which includes a no-bottle/no-fill feature, tracks the fill of each Continued on page 26 ES220889_PD1304_024.pgs 03.27.2013 01:58 UBM

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