INNOVATION IN BEVERAGE TECHNOLOGY

Transcription

1 PET Engineering, a leader in PET containers design for the beverage industry, offers a qualified and complete service covering all the aspects of the bottle industrialization process: design, mould projecting and delivery, rapid prototyping and advanced training. PET Engineering s strength lies in the awareness of technical issues and needs related to the final container image. The company is able to support the entire project, ensuring the quality of the bottles, the design, the adaptability of the moulds into the existing machinery, and the return on investment through all the savings achieved in the production of new containers. P.E.T. Engineering S.r.l. Via Celtica, 26/28, Z.I. Ungheresca SUD San Vendemiano (TV) Italy Tel Fax info@petengineering.com - BBM Service Srl, was created when the founders had been working on this sector for twenty years, and nowadays it is an evolving company appreciated by its customers in all the countries where it operates, placed on the market as a company specialized in packaging and industrial packaging. Its structure is organized to provide full support to the customer. The team consists of a group of specialists, a technical department which builds and develops special solutions and a commercial staff prepared and competent who builds flexible solutions to meet real needs. INNOVATION IN BEVERAGE TECHNOLOGY BBM Packaging S.r.l. Via Pregalleno, San Pellegrino Terme Bergamo (BG) Italy AGR Int. is a global leader in the development of systems and equipment for quality check control for the beverage and packaging industry. Its products and services are developed based on the specific needs of each customer, from planning, consulting, on-site evaluation of the system to be implemented until the staff training. AGR from over 65 years has been working with the major world producers of glass and PET containers in order to guarantee, throughout a continuous research and study of customized advanced solutions, a better final quality product and an improved production efficiency. 615 Whitestown Road - Butler, PA USA Tel Fax marketing@agrintl.com

2 News. A real progress is only when benefits of a new technology are for all (Henry Ford). A new project, that is to say, the development of a new technology, it is not always synonymous with new machinery, new systems or new equipment. A new technology can also be defined as an application to an existing element with the aim of improving its final performance and efficiency. Polaris is a new technology, designed and developed by a team of companies that have been operating in the beverage sector for several years, which provides new identities to existing machines, outdated or no longer able to meet today s production demand. This project represents an important innovation within the market: for the very first time different solutions have been developed,tested and implemented individually or together on old generation blowing machines with the aim to achieve the same final performance of the last generation blowing machines, with a guaranteed low cost fare and short term investments with quick returns.

3 The future is light! The future is light! An apparently common product such as plastic bottle hides a quite complex process of development. Today s market forces container shapes to be more attractive, as well as easy to handle and with less environmental impact. On the other hand, beverage producers aim to reduce costs, considering the increase of the price of raw materials. Today s trend is oriented towards weight reduction (LW), starting the a preform project, continuing with the development of the bottle design, until the final container s production on the filling line. Preform project Bottle design development Container s production on filling line In this context, every equipment should support and satisfy in terms of performance in the inherent technologies of the new products. The technology of the machines is at the service of the technology of the product in order to meet a real market demand. P04 _05

4 Eco-VOLUTION: savings and evolution. Eco-VOLUTION: savings and evolution. Eco-VOLUTION: savings and evolution. Today, the word evolution assumes a dual meaning: technology and economy (saving). The new solutions are intended to ensure high level performances and at the same time guaranteeing savings. POLARIS represents the perfect match between evolution and savings. It s a precise result based on a customer-oriented policy, extremely attentive to the market needs capable of developing advanced solutions that provide savings at the same time. LW Allows the production of lightweight PET containers with old generation blowing machines Q.C. implementation of advanced systems for quality control purposes UP innovative mechanical solutions applied to old generation blowing machines SAVING 3 key elements that make up the POLARIS SAVINGS FORMULA: Saving on buying raw material Saving on buying a new generation blowing machine Savings on energy consumption Savings on waste reduction into PET container production P06 _07

5 The project. Lamps pitch changing The project. Replacement of solid state relay POLARIS consists of 5 modular solutions that can be implemented individually or together on the blowing machine. This flexibility, produced by these modules, allows each customer to customize these solutions according to the production capacity. The project was developed, tested and proven on the field by PET Engineering together with BBM Service Srl and in collaboration with the American AGR Int., all companies that have been working for several years in the beverage sector which makes them being aware of new trends and market needs. A partnership built in 2010 with the aim of offering advanced solutions, customized and sustainable, within a continuous research and development. Three companies, one voice, with the willingness to be an unique partner for every need. Implementation pet wall profiler process pilot Replacement of blowing valves group Air recovery system P08 _09

6 POLARIS 1. POLARIS 1. Lamps pitch changing. The intervention is focused on changing the rack lamp holders by providing a brand new support having 15mm pitch, to permit more radiation on the preform s body inside the oven. This support is made of stainless steel and is installed on an appropriate hollow made on the existing frame that is modified by an operation with a milling machine. This solution allows a massive costs reduction due to the fact that the replacement of frames can be done in short time with a reduced production stop. No changes on the main logic of the oven management device and cabinet hardware will be done. Before After P10 _11

7 POLARIS 2 POLARIS 2. Implementing SSR (Solid State Relay). The replacement of the existing relay with this new one, having this new pilot technology pwm, creates an optimized lamp adjustment in various sections of the oven which at the end permits a significant energy saving. Depending on the number of the sections in the oven, a specific number of devices is expected. The integration of this type of adjustment device changes the electrical cabinet and its consequent wiring and testing are made by our qualified personnel. Each device has a logic control integrated together with the power that supplies energy to the lamps. These devices have the capability to be controlled by the most common communication systems in the market, in the case of machines with BUS systems that may be implemented in the future if they are not equipped. P12 _13

8 POLARIS 3. POLARIS 3. Substituting the blowing valves group by electro-pneumatic control and central manifold. The replacement of control valves, on the pre-blow and blow phases, is carried out by an electro-pneumatic control. All valves are replaced and the system is integrated with a series of additional controls and electronic devices Group of valves at electronic control. Main features: high-performance in terms of flows and pressures; reduced switching times and high repeatability of the drives; built-in Non-return valves low maintenance costs; function lube free ; valve body with hard-anodizing scratch proof coating; All valves of cavity, are linked to a single sub-base that is used as a connection between primary and secondary blowing air. To this sub-base are also connected some auxiliary components like the derivation box and connectors, the unloader and the working pressure control chesking valve. This last valve contributes significantly to the efficacy of managing the waste of any bottles with holes presence. Replacing the mains air collector. The installation of this new group of valves requires the replacement of the main collector in order to distribute electrical signals into the valves. Main features of the collector: Long lasting duration of mechanical parts subjected to wear out; High-flow rates and operating pressures of the blowing compressed air; Keeping high quality standard of blowing air due to the absence of any contaminant agents into the flow channels Sliding-electrical contact having high performance and hardness (400HV); Multiple-channel for I / O command signal and control of electrical devices located in the blow wheel with the capability to manage serial BUS communication system type; Separate channels for power supply devices located in the carousel. Control panel and operator interface HMI. The blowing phase sequence, which is made with a mechanical cam system, is taken over by a brand new technology of programmable logic by setting the blowing parameters directly from the operator s control panel. Main features of the Interface menu. Through specific program pages, the operator is able to interact with the machine through settings, different types of parameters and displaying different information. Among these various options, we highlight the most interesting ones for the blowing machine operator and the maintenance operator. Blowing machine configuration; System configuration; Viewing the status of the components and blowing process; Selecting functions and qualifications of manual controls; Configurating parameters and recipe menu and saving them into the hard-disk and the memory store; Cam setting-up that controls the blowing process of the electro-valves through specific operation windows; Pressure control; The management of leads and lags. The management of leads and lags allows to enter deviations on more leads or less lags compared to the cam value according to basic recipe; The management of the preform presence that determines the operation of the cavity where it will be located; The setting parameters of bottle extraction. P14 _15

9 POLARIS 4. POLARIS 4. Compressed air recovery. The air recovered used during the blowing process is carried out by an integration of different types of pneumatic components (tank depot, electrically operated pneumatic valves, safety valves, pressure transducers, etc..) into the blowing machine. The air used for blowing the bottles is partially recovered and stored in a tank depot built in the carousel that can be re-used in the pre-blowing phase and / or produce air service for the carousel (stretching and nozzle cylinders, etc.). The air recovery value depends on the initial blowing pressure and on the pressurization value of the tank depot. The higher is the blowing pressure, the greater the air amount recovered will be. The implementation of the fourth module apermits a drastic reduction of energy consumption of the blowing machine due to reduced absorption of the high-pressure compressed air. P16 _17

10 POLARIS 5. POLARIS 5. Implementation of PET PRO Wall process pilot. Quality: synonymous with added value and savings. The 5 th module provides the implementation in the blowing machine of the last generation device from AGR Int., PET Wall profiler process pilot. The Pet wall profiler system permits a real-time control of all the containers produced. The reading device positioned on the blowing machine, with 32 miniaturized sensors (whose number depends on the height of the bottle), can detect the wall thickness of each bottle produced with extreme precision. It interacts directly with the machine for the waste of non-standard quality containers highlighting the cavities that had been produced, or any problems within the preform heating oven. The addition of the process pilot allows also the adjustment of the blowing parameters as well as the values of the levels of preforms heating inside the blowing machine oven. This system has a special closed loop control which makes a real-time feedback and therefore it is able to modify the current values and optimize the process to obtain a high quality product. Its implementation has several benefits, such as: greater production efficiency, significant reduction of non-standard products and waste of raw material, increasing the quality of the product, with savings in terms of time and cost. The system consists of miniature sensor supports, an industrial operator interface panel (HMI) and the electrical control and command panel. The device is able to work and interface with either the blowing machines having the latest generation PLC, and with those having S5 PLC type still existing. This solution was designed and developed in partnership with AGR Int.. P18_19

11 R.O.I. R.O.I. Ordinary men looks at the new things with old eyes. The creative man observes the old things with new eyes. (G.P. Bona) POLARIS responds to the needs for adapting old machines to the latest standards of performance imposed by the market without buying something new, ensuring energy savings, improving the machine performance, the production efficiency as well as giving the possibility of producing lightweight containers. The flexibility of the project allows each customer to assess different modules to be implemented on their blowing machines, depending on their production needs. Any combination of modules provides benefits, and, if associated with a weight reduction of the container produced, the savings are greater and it will provide short term investments with quick returns. These quick returns, on the basis of different module combinations that can be implemented, are graphically identified by a hyperbole, the economic return is placed on the Y axis, while on the X-axis the possible weight (g) reduction of the container is situated, and all this is now possible thanks to Polaris. The ROI of the investment turns out to be faster when POLARIS is related to a lightweight container project. The lightweighting is the key to gain the most benefits in short term: the greater the weight reduction is in terms of grams, the shorter will be the time to return to the initial investment and obtain savings. This graphic represents general data and some possible solutions. The ROI will be calculated step by step based on the real situation of each customer. P20_21

12 NOTES P22_23