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Service and Integration of Bottling Controls
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“Project: Middle English projecte, from Medieval Latin projectum, from Latin, neuter of projectus, past participle of
proicere to throw forward, from pro-jacere to throw”
(Merriam Webster dictionary definition of “Project”, an Encyclopedia Britannica Co., 2014)
Design
Twenty years ago we entered the Food and Beverage field after years designing in a
Technical Department the electronic circuits and automations of Packaging Automatic
Machines.
We spent past two decades on side of the SASIB Beverage™ / SIG® / Tetra Laval Sidel® designers and project managers of the Layout, System Engineering, Procurement
and Project Management Departments:
examining Vendors’ offers,
preparating electronic inspectors Minimum Requirements,
controlling and fine-adjusting tens of new Lines’ layouts or upgrading the preexisting,
Designing conveyors, sampling, electronic blocks, reject accumulation tables, in
presence of electronic inspectors,
integrating Electronic Inspectors,
meeting Customers preferances, choosing the Inspectors’ Optoelectronic
configurations optimised for their products and peculiarities;
root cause analysing tens of failed Packaging Line Layouts.
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To upgrade a Bottling Line also means to be sure before the upgrade shall not reveal itself later (when it’s too late) an
unexpected ashaming downgrade. When SIG® / Sidel® / Tetra Laval® received the order by Cerveceria Modelo S.A. de
C.V.® to upgrade tens of its glass bottle filling lines in Mexico for new technology linear Empty Bottle Inspectors, we have
been asked to study all the inherent fine-details, so to assure full success to the upgraded Lines. They are still today
successful
Design and system-integration
To design a winning Layout does not signifies to oversize bottles’ accumulations,
distances and tons of the expensive Conveyors’ stainless steel. Remember the V2
rockets which started to fall over London after 1944 ? They were single-stage rockets.
What should have happened if Werner Von Braun should have continued to follow such a
design-strategy for its Saturn V rocket destined to the Moon, rather than to pass to the
mathematician K. E. Tsiolkovsky multi-stages concept? Surely the first Man on the Moon
should have been …Russian ! Von Braun had to think in a wider space, understanding
Tsiolkovsky’s theoretical demonstrations established strict physical limits: a new design
address, different than his own V2 was necessary to let the Lunar Project be some years
later a successful one.
This is true also in our Food and Beverage Bottling Lines, when acting to assure success
to a Layout’s design. What means ...project ? Following the Merriam Webster dictionary
(an Encyclopedia Britannica Co., 2014) ethimological definition: “Middle English projecte,
from Medieval Latin projectum, from Latin, neuter of projectus, past participle of proicere
to throw forward, from pro-jacere to throw”.
To project something really means to imagine all what should later happen, if a very long
row of design choices should be made factual. It’s like to study in what a way a tree of
identified botanical variety, shall thinkably grow along future 10, 20, 30, …, 50 years, if
planted there, in that season, on that ground, with that solar exposure, close to those
other trees, etc. etc….. who, what, when, in what extent plus their complementary
excluded amounts and categories. 25 centuries old canons of Philosophy, revived in the
way to create a successful Project or to Root Cause Analyse an effect.
To assure success to a Layout first of all implies a deep and true comprehension of
the Customer's fundamental desires and of the eventual criticities implicit in these
desiderata.
One time this comprehension is considered complete, it is necessary to pass to the
second step, how the Customer wish list can be made factual.
This is the phase where an initial temptative Layout is drawn. In this phase, it is necessary
to really know:
each one Machine in the Layout. What each one Machine (or Device, like the
Inspectors) needs in terms of containers accumulated before, of spaces available
later, distances between containers and their maximum deviations, temperature of
the containers, etc.
overall correlation between Machines, Conveyors, Services. A banal example
being the vital necessity to assure Operators and Maintenance staff an adequate
space to access the Machines. An operative condition perfect for a Machine 50
meters afar and before can imply an impossibility to let another operate correctly.
When summing Design activities to those of Field Service Engineering, the total number
of SASIB Beverage™, SIG® and Sidel® (Tetra Laval Group®) Bottling Lines where the
technical solutions designed by our staff are being applied jumps to nearly 300. Just an
example visible in the different figures above, showing details of the Layout of the 60000
bottles-per-hour glass returnable Bottling Line of Yantar® Brewery
(http://www.yantar.ua/index.php?page=asorti) at Nikolayev, Ukraine (a SABMiller
(http://www.sabmiller.com/)® company). Here, we redesigned in 2008 positions and
configurations of the Electronic Inspectors. A value added to Bottling Line masterplan:
that Layout was preferred to competing offers by other OEMs and is since 2009 running
and productive.
Seasoned running examples are the tens of Grupo Modelo®
(http://www.gmodelo.mx/index.jsp) (an ABInbev (http://www.abinbev.com/)® company) glass returnable Bottling Lines in Mexico filling the Corona® beer
in the bottle visible here on right side. For these Beverage Bottling Lines our staff (in the
meantime installing, system-integrating, starting and commissioning also the then fastest
Linear EBI of the world in Yarpivo® at Yaroslavl, Russia, a Baltika® Group company), in
Spring 2003 redesigned a new optimized Line Layout. This new Layout was made
necessary when Grupo Modelo® decided to replace tens of rotary EBIs with tens of
Linear EBIs.
Cerveza Corona™, is bottled in
Mexico by Cerveceria Modelo®,
S.A. de C.V.. Its Quality and safety
is assured by many tens of glass
returnable Empty Bottle Inspectors.
The tens of newly upgraded Layouts
all-around these EBIs, Electronic
Blocks, accumulations and reject
tables, we were asked to study and
100 - 250 inspections
optimise, front of the limited preexisting spaces in May 2003. We
accomplished the design activities,
when commissioning in the
Tens of other examples, are running in a long row of Sidel®’s Lines. In November 2010
we designed and integrated the Heuft® Systemtechnik Full Bottle Inspectors
(FinalView™ or Squeezer™ models) with the Sidel®’s Aseptic Blocs, including AROL’s
Cappers. Design and execution of an interfacing allowing to reduce thousands of times
the occurrences in the Market of the open then dangerously contaminated bottles. One
with sensors in-the-machines, operating at a speed 1.5 m/s at 52000 bottles-perhour. Devoting tens of parallel-working CPUs to the simultaneous management of 1.1
millions/day of bottles univoquely identified along the combined areas featuring:
over 100 Aseptic Filler valves;
24 Capper's heads;
12 meters of conveyor after the release point of the Capper's out feed starwheel.
meantime other 7 Heuft® and
Stratec® Electronic Inspectors in 2
new glass and PET bottling Lines in
Russia along May 2003 for the
Customer Yarpivo®, Baltika Group®
itself part of Carlsberg Group®.
Next time you’ll drink a
Corona™ mind we are also direct
Actors of those many successful
Projects in Mexico (image abridged
made available under CC 3.0
(http://creativecommons.org/licens
es/by/3.0/))
This way, the innovated Bloc became the first worldwide having its internal aseptic filling valves and capper heads, associated to
their own indipendent inspections, integrated by a rigorously synchronised Electronic Inspector, having its own independent
inspections. Electronic Inspector providing the rejection device and way-out for each bottle designated to rejection.
We are speaking of a Bloc's grand total amount of inspections :
reciprocally independent;
based on different physical principles;
which, following the size and model of the Bloc ranges (100 - 250).
With always at least 4 inspections applied to each one individual bottle, to increase the knowledge of the physical property
being measured in the object, increasing this way Food and Beverage safety. (A condition of maximum knowledge which could
only be met by a single measurement device if the interaction could last along an infinite time).
Conditions for maximised Food and Beverage safety, which may be synthesized as measurements which have to be:
consecutive;
reciprocally independent;
based on different physical principles.
This is the only true and real way to reduce over 100 times the amount of Customers contaminated drinking by bottles which
stood too long time in the Bloc, which had their cap non perfectly closed when applied, which had their cap non perfectly closed
when checked in the Full Bottle Inspector. 100 times less than what an Electronic Inspector can do operating standalone. To
have two independent consecutive Electronic Inspectors processing the same bottle on the same conveyor, should not allow to
equal these levels of Food and Beverage safety, on the opposite we’d ameliorate only ~10 times. Why ?
The reason lies in the fact that:
Torque inspections, in each head of the Capper Machine;
Time (and other parametric) inspections in the Filler Machine;
are based on physical principles different than the mere electromagnetic of the Cap inspections existing in today's cameraequipped Cap Visual inspections. From a much deeper point of view, this is a consequence of the exploration of a wider section
of the Hilbert space, where fully and really the capped bottle exist. It implies the extension of the measurement to the
eigenvalues of additional eigenvectors.