Uhlmann's IBC 200 Boosts Bottle Line Performance

A common drive and control system promotes equipment and line efficiency in the Integrated Bottle Center 200 (IBC 200) from Uhlmann Packaging Systems (Towaco, NJ). Equipment efficiency, or real output of packages that meet quality criteria compared with set output, is in the 98% range, says Dirk Corsten, managing director.

A feed screw system eliminates jam ups and congestion by providing seamless transport of bottles from loading station to discharge. “We talked with hundreds of people in designing the IBC 200, and everyone’s key concern was productivity,” Corsten says.

“Every micro-stop [in a traditional line] causes a stop in the whole line [in lines configured with multiple conveyor transfer systems]. We have one conveying system by means of feed screws that takes on the bottle at the beginning and guides it through without any potential issues arising from loss of control,” Corsten says.
Push-button menu-based changeovers minimize planned downtime for batch and parts changes.

Machine settings are reset and repositioned at the push of a button for changeovers with bottles of the same diameter.

For when container diameters change, feed screws are provided in format sets. “There are no adjustable parts requiring operator expertise. Screws are clicked in toollessly in 10 to 15 minutes, and you are ready to go,” says Corsten. The investment in the format sets is offset by the increased productivity derived from the decreased ramp-up time.

A central operating system controls all line functions, with SCADA software for line control and analysis. “We are typically providing SCADA software for a complete packaging line that might include third-party equipment such as unscramblers and palletizers,” he says.

The SCADA features tools that guide operators in making improvements. Data can be sent for further detailed evaluation to ERP systems or conveyed to web-based applications from which lines can be monitored and also controlled.

A master shift register tracks the production status of every bottle. “This follows the 100% good package philosophy we use with all of our machines. Every product is defined as a bad product when it enters the line, and must pass security checks along the way. The filling station knows not to fill a bottle [lacking] a desiccant, [for example], and the bottle is marked for rejection. Good bottles with the right count, desiccant, torque, and induction seal–force are discharged to an outfeed conveyor for further packaging,” he says.

Rejects are conveyed on a second belt, with a third conveyor dedicated for in-process control. Sequenced bottle ejection for QA can be programmed by count or hour for presenting bottles for inspection without stopping the line.
Bar code printing, scanning, and code verification can be integrated for coding and data generation for e-pedigree.
“All of the quality-relevant data are stored in the shift register. Customers can keep it on record to support recalls or other tracking requirements,” Corsten says.