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, labelling, 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
Flexlink Conveyor
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 organised 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 should operate continuously across three shifts and include a modular conveyor to assist with bottle filling, capping, and tightening. The line also employs a Fanuc M10iA robot to handle the filled and capped bottles, which are transported by a secondary conveyor. Each box with a capacity of 4 bottles should be filled within 10 seconds, while larger boxes holding 8 bottles should be filled within 20 seconds. The conveyor should be designed to meet these cycle times, move simultaneously, and integrate seamlessly with the existing production line according to the manufacturer's instructions.
Solution
Based on the project scope, we developed a custom conveyor system tailored to the production line and environment. Its modular design allows for easy customization and expansion to meet specific production requirements.
- The conveyor's shape and size were determined by the product's (bottle) dimensions, weight, fragility, and throughput requirements.
- Since this application is designed for the food industry, we selected stainless steel with food-grade material for the conveyor to ensure easy maintenance and safe usage.
- The conveyor system is built with durable components to ensure long-lasting and reliable performance. Factors such as temperature, moisture, and humidity in the production environment were also taken into account during the selection process.
- The linear bottle transfer FlexLink Modular Conveyor system is specifically designed to transport empty bottles to filling, capping, and labeling stations.
- The FlexLink Modular Conveyor system is designed to transfer bottles within a carton box and is suitable for various material handling applications. A rough guide prevents Carton box slippage from the conveyor, and the adjustable leveling feet allow for height adjustments.
- The conveyor length can be extended by adding FlexLink modules. It is flexible and can be customized to angles between 90 and 180 degrees, as well as configured in a U-shape. Its compact and flexible structure minimizes footprint while maximizing operational efficiency.
- All safety and ergonomic standards are met according to the client’s requirements. The proposed solutions were developed with careful consideration of DFMEA (Design Failure Modes and Effects Analysis).
Value and Benefits
Choosing the right conveyor for an automation machine in the food industry involves evaluating material, operational, environmental, and regulatory factors. Our new machine significantly boosted production speed and throughput, exceeding the client's targets. By addressing key challenges and using advanced technology, our bottle filling and capping machine exceeded expectations. The conveyor system seamlessly integrates with other automation systems, enhancing productivity. It handles a wide range of products, offering versatile solutions. This project improved efficiency, ensured high-quality standards, and provided flexibility for future needs, showcasing our commitment to innovative solutions in the food and beverage industry.
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