Our client, a leading company in the beverage industry with a substantial market share in bottled water and soft drinks, aimed to boost their production efficiency. They required a comprehensive and advanced bottle filling and capping machine to enhance throughput, and maintain consistency, with improved product quality. The new system needed to handle high production volumes and integrate seamlessly with their existing production line. We designed a comprehensive bottle capping assembly line featuring filling, capping, labeling, and packing units. The system is engineered to fill a box containing 4 bottles in 10 seconds and a larger box with 8 bottles in 20 seconds.
Material Handling
Bottle Capping Assembly
The customer boasts over 50 years of experience in the food processing industry and has been a leading beverage seller for over 40 years. With nearly 32% of the market share in the organized bottled water segment in India, they compete with major brands. Their products are also distributed across Europe, Asia, and North America.
Scope
Challenge
The bottle capping assembly line is designed for continuous operation across three shifts, featuring both filling and capping stations with secure tightening. The client required a machine capable of high-speed, accurate handling of large volumes of bottled beverages, with each bottle being filled in 2 to 3 seconds. Ensuring consistent filling levels and secure capping was crucial for meeting industry standards and minimizing product waste. The line incorporates a Fanuc M10iA robot to manage the filled and capped bottles, which are transferred to packaging via a separate conveyor. A small box, holding 4 bottles, is filled in 10 seconds, while a larger box, holding 8 bottles, is filled in 20 seconds.
Solution
Based on the project scope, the filling station is designed to fill 4 bottles sequentially. As bottles approach the conveyor, 2 pneumatic cylinders are used to separate and position the bottles for filling. optical sensors detect the liquid level in the bottles to prevent overfilling or underfilling. The station also includes a vertical cylinder and flow sensors to ensure consistent filling. After filling, each bottle is capped and positioned at the capping station using a servo indexer. Inductive sensors ensure precise alignment of the bottles and caps. Capping is managed by a vertical slide cylinder and a rotary gripper, aided by a cap sensor for positioning and a torque measurement sensor to ensure the caps are tightened to the correct specification. Nylon fingers securely hold the cap during the tightening process. After capping, the bottles are labeled by the labelling unit and then transferred to the bottle transfer conveyor. Through-beam sensors are used for counting bottles. Once the designated number of bottles is transferred and stacked, the Fanuc M10iA robot picks up 4 bottles at a time and places them into cartons of specified sizes. The robot is equipped with a state-of-the-art End Of Arm Tool (EOAT) designed by our team for precise bottle handling. We used safety door switches to protect and detect any intrusion into hazardous areas and installed emergency stop buttons to shut down the system in case of an emergency. Advanced sensors were utilised to optimise the filling and capping process, ensuring product quality, reducing waste, and enhancing safety, all while complying with the customer’s safety standards.
Value and Benefits
The new machine significantly enhanced production speed, handling up to 80 bottles per minute. This increase in throughput met and exceeded the client’s production targets.
Our advanced bottle filling and capping machine surpassed the client’s expectations by addressing key challenges and integrating state-of-the-art technology. We delivered a solution that improved production efficiency, ensured high-quality standards, and provided flexibility for future needs. This project highlights our dedication to delivering innovative and effective solutions in the food and beverage industry.
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