Bottle Filling Process - Technology, Machines, Methods and Motions - Productivity Improvement - Industrial Engineering

Machine Effort Industrial Engineering - Bottle Filling Process - Technology, Machines, Methods and Motions - Productivity Improvement

Collection of improvement to the bottle filling lines to illustrate engineering and productivity improvements. As industrial engineers, we understand the productivity development over number of years by following the history of various engineering processes. We need to carry out productivity improvement in the processes of the organizations where we are working based on the accumulated developments in engineering related to those processes.

Coca-Cola Production Step by Step

https://ru.coca-colahellenic.com/en/operations-in-russia/production-step-by-step

Automation Parts Supplier - https://americas.rsdelivers.com/

2021

A new state-of-the-art plant for Coca-Cola Bottling Company United in Baton Rouge, LA. 

Four flexible packaging lines  

May 7th, 2011

Four lines produce 120 skus

• Line 1 handles 12-oz soft drink cans at 1,800/min, packaging them in a range of case sizes

• Line 2 fills 1- and 2-L and 20-oz PET bottles of sparkling (or carbonated) beverages at up to 800/min

• Line 3 accommodates 12- and 20-oz and 0.5-L PET bottles of both sparkling beverages and Dasani water at speeds to 800/min

• Line 4 hot-fills 20- and 32-oz PET bottles of Powerade sports drink at speeds to 800/min

https://www.packworld.com/machinery/primary-packaging/video/13348587/new-coke-plant-designed-with-future-in-mind

Mitsubishi Electric's motion controller CPU (based on the iQ Platform)

The aspect of ensuring that the control of the filling nozzle is completely synchronized with the rotational conveyor and flow controller is the challenge for most bottle filling applications. The controller has to ensure that the liquid is fed accurately into the bottle opening. The flow rate and nozzle height also have to be precisely controlled to eliminate the risk of frothing and overflow of the liquid itself.

By using Mitsubishi Electric's motion controller CPU (based on the iQ Platform), cam profiles can be controlled intelligently with software caming systems that replace hardware based methods which are prone to error and profile deviation.

In addition to the motion controller, the actual transfer and conveyor aspects of the application can be controlled using Mitsubishi Electric's intelligent and energy saving drives. These are integrated into the total system via the open device level network CC-Link. The fast rates of bottles being fed into the machine can be controlled by the System Q together with a CC-Link network, offering high transmission speeds of 1 Gigabit with program speeds in the milliseconds. The System Q also enables connectivity to upper level control and management systems via its Ethernet option module allowing real-time production data to be fed into ERP/MES systems.

https://eu3a.mitsubishielectric.com/fa/en/solutions/industries/packaging/bottle

60 to 300 BPM machine

Rs. 11 lakh  (Rs. 1,100,000)

24 BPM Line

Rs. 8 lakh (Rs. 800,000)

https://www.aimpackindia.com/bottle-filling-machine.html

2020

2020-05-19

Coca-Cola Co set up the world's fastest bottling line recently in Chengdu, capital of Southwest China's Sichuan province, as the United States-based global beverage giant looks to further expand its manufacturing capacity and investment in China.

The new line at COFCO Coca-Cola Beverages Ltd (CBL) can make 120,000 cans every hour, making it the fastest fully automatic production line in the world, according to Ching Lijun, CEO of CBL. The current industry average is between 66,000 cans and 90,000 cans every hour.

https://www.chinadaily.com.cn/a/202005/19/WS5ec3260da310a8b2411569a7.html

2019

Bottle Filling Machine with 21 CFR Part 11 Compliance Batching Control

Automation of Bottle Filling and Airless Pump Snapping Machine

Amit Bharadva

Co Founder at Luova Technologies Pvt Ltd.

https://www.linkedin.com/pulse/automation-bottle-filling-airless-pump-snapping-machine-amit-bharadva/

Reasons to Use Nichrome’s Automatic Bottle Filling Line for Liquids

https://www.nichrome.com/blog/reasons-to-use-nichromes-automatic-bottle-filling-line-for-liquids/

Design of Digital Twins for Optimization of a Water Bottling Plant

Publisher: IEEE

Cite This

PDF

G.A. Gericke; R.B. Kuriakose; H.J. Vermaak; Ole Mardsen

Published in: IECON 2019 - 45th Annual Conference of the IEEE Industrial Electronics Society

Date of Conference: 14-17 Oct. 2019

Digital Twin can replicate physical assets, processes and systems that fulfill the various processes in a real world plant. This paper looks at creating a Digital Twin for the optimization of a water bottling plant in a production line. The Digital Twin utilizes an Open Platform Communication server to collect sensor information from the production line through a PLC. Once the Digital Twin has processed the information, the applied solution can then be sent back to the Open Platform Communication server and read in by the individual PLC's to reduce bottlenecks and production delays. This is accomplished by setting up a Digital Twin with three SMART Manufacturing Units that are tasked with the production of 500ml water bottles. Here premade 500ml bottles are fed into the system, filled by the first SMART Manufacturing Unit, capped by the second and thirdly packaged to order. The Digital Twin will be used to analyze the performance of the SMART Manufacturing Units connected in a production line. This performance can then be used as an estimation of how well the physical production line can hope to perform and give an indication of time to market.

https://ieeexplore.ieee.org/document/8926880

Bottle Production and Filling in Coca-Cola Plant

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https://www.youtube.com/watch?v=9Eq4C9ch-vk    (Read comments)

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2018

http://www.tagajournal.com/gallery/v14.146.pdf

https://www.researchgate.net/publication/328064911_Improvement_in_Productivity_of_Bottle_Filling_Operation_by_using_Multi-Nozzle_PLC_System

2013

Machine vision boosts productivity on bottling line

Mar 7th, 2013

IE Case Study: Machine vision Based Inspection Productivity Improvement on Bottling Line - 2013

https://www.machinedesign.com/automation-iiot/sensors/article/21832428/machine-vision-boosts-productivity-on-bottling-line

2010

https://peer.asee.org/an-automated-bottle-filling-and-capping-project-for-freshman-engineering-students.pdf

Simulation-Based Analysis and Productivity Improvement of a Fully Automatic Bottle-Filling Production System: A Practical Case Study

Publisher: IEEE

Tarek Al-Hawari; Faisal Aqlan; Mu'aweyah Al-Buhaisi; Zaid Al-Faqeer

In this paper, a simulation study was carried out to improve the productivity of a fully automatic bottle-filling production system. An in-depth analysis of the system was performed in an attempt to increase its throughput and overall productivity. A simulation model was developed for the current system to ascertain its limitations and problems. The relevant performance measures are analyzed and a set of changes and improvements to the actual system were proposed. Furthermore, an optimization study on the relevant parameters was conducted in order to find the values that lead to increased productivity and throughput. In addition, downtime analysis was performed using statistical techniques to optimize uptime and reduce machine failures. Simple actions were suggested which can lead to considerable increase in efficiency, productivity and profitability of the system.

Published in: 2010 Second International Conference on Computer Modeling and Simulation

https://ieeexplore.ieee.org/document/5421488

2008

https://repository.up.ac.za/bitstream/handle/2263/11179/Jooste_Productivity(2008).pdf?sequence=1

Production and Packaging of Non-Carbonated Fruit Juices and Fruit Beverages

Philip R. Ashurst

Springer Science & Business Media, 30-Apr-1994 - Technology & Engineering - 429 pages

In the period of about five years since the first edition of this book appeared, many changes have occurred in the fruit juice and beverage markets. The growth of markets has continued, blunted to some extent, no doubt, by the recession that has featured prominently in the economies of the major consuming nations. But perhaps the most significant area that has affected juices in particular is the issue of authenticity. Commercial scandals of substantial proportions have been seen on both sides of the Atlantic because of fraudulent practice. Major strides have been made in the development of techniques to detect and measure adulterants in the major juices. A contri bution to Chapter 1 describes one of the more important scientific techniques to have been developed as a routine test method to detect the addition of carbohydrates to juices. Another, and perhaps more welcome, development in non-carbonated beverages during the past few years is the rapid growth of sports drinks. Beverages based on glucose syrup have been popular for many years, and in some parts of the world isotonic products have long featured in the sports arena. A combination of benefits is now available from a wide range of preparations formulated and marketed as sports drinks and featuring widely in beverage markets world-wide. A new chapter reviews their formulation and performance characteristics. Another major trend in the area of fruit-containing non-carbonated bever ages is the highly successful marketing of ready-to-drink products.

https://books.google.co.in/books?id=ocZhAHR5Ne0C

Ud 4.10.2021

Pub 26.6.2021