Design considerations for packaging lines

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1 Design considerations for packaging lines Jonathon Stewart Krones UK

2 krones GL Beispieltext Summary Overiew of Krones Line Operation -

to warehouse - material flow Automated line control - conveyor

supply disposal quality checks reporting change over preventive

2 2 krones GL Beispieltext Summary Overiew of Krones Line Operation - No. of people - Realistic amount of work Line logistics - connection to warehouse - material flow Automated line control - conveyor buffers -V curve operation monitoring trouble shooting material supply disposal quality checks reporting change over preventive action CC-en31-p /10 CC AB Line design is always a compromise focus on priorities

3 3 krones GL Beispieltext Krones filling and packaging technology 300 turnkey lines for beverages p.a. 50 turnkey lines for beer p.a

4 4 krones GL Beispieltext From very small to very big 5, b/h b/h b/h

5 5 krones GL Beispieltext The optimal line design Line operation - What are the main duties of the operators? - What should we as a machinery supplier consider during the design phase? CC-en31-p /10 CC AB

6 krones GL Beispieltext The optimal line

minute 500 caps per minute 1,000 labels per

6 6 krones GL Beispieltext The optimal line design Line logistics - connection to warehouse - material flow Based on 30,000 bph line 42 cases per minute 500 bottles per minute 500 caps per minute 1,000 labels per minute CC-en31-p /10 CC AB 250l beer per minute

7 7 krones GL Beispieltext The optimal line design Line logistics CC-en31-p /10 CC AB

8 krones GL Beispieltext The optimal line design - The v-graph V 125% 120% 110% 100% 110% 120% 125%

modified due to customer specification or line related reasons Up and downstream machines in reality

filler speed Nominal line speed + overspeed = nominal machine speed + rate of rejects, empty partitions,

8 8 krones GL Beispieltext The optimal line design - The v-graph V 125% 120% 110% 100% 110% 120% 125% depalletiser EBI Rinser Filler/capper labeler Packer palletizer Krones Standard V-curve V curve can be modified due to customer specification or line related reasons Up and downstream machines in reality often run permanent on over-speed due to recovery times The speed of the line = nominal line speed = the filler speed Nominal line speed + overspeed = nominal machine speed + rate of rejects, empty partitions, none production bottles (if more than 3%) Example: A labeller has to be designed for a nominal speed of 110%

9 krones GL Beispieltext Buffers to protect the

lead can produce continuously without stoppage as

9 9 krones GL Beispieltext Buffers to protect the lead machine Ensure continues production on the lead machine in case of upstream and/or downstream stoppages Buffer time: the time the lead can produce continuously without stoppage as a cause of the downtime of upstream and/or downstream

10 10 kronesbeispieltext GL Overspeed to recover the buffers Machines before and after the lead machine have overspeed to recover the buffers. The time they need is called recovereytime Speed up to fill! Buffers before the lead should be filled Speed up to empty out! Buffers after the lead should be empty

11 11 kronesbeispieltext GL Basic design parameters MTTR = Mean time to Repair Average time to do trouble shooting on a machine. This time only reflects micro stoppages = short interruptions no break downs. The buffer should be at least as big as the MTTR + 50% MTBF = Mean time between failures Average time between two micro stoppages. The buffers should be recovered before the next potential failure might come up. MTTR and MTBF therefore are the basic parameters to calculate the over speed MTTR t Buffer Over speed V-Graph MTBF t recovery Considering cost-value-ratio

12 12 kronesbeispieltext GL Relation between over speed and buffer As bigger a buffer as more time it takes to empty it out. Chart below shows the relation between overspeed buffer and recovery time Krones suggests +10% over speed on lead machine near machines (upstream or downstream 10% means: (chart) it takes 10 minutes to recover 60 seconds of buffer with 10% over speed. Or it takes 20 minutes to recover a buffer of 120 seconds. Or with other words: If the failure frequency on the machine is up to 10minutes (poor performance) and the failure takes 60seconds there will be no impact on the lead machine

13 13 kronesbeispieltext GL What does a buffer system look like? Accumulation table after the lead machine Over speed Lead Machine Multi lane conveyor acts as a buffer system Over speed

14 Thank You!

PACKING LINE SAVINGS IN THE FOOD AND DRINK INDUSTRY

GG243 GUIDE ENVIRONMENTAL TECHNOLOGY BEST PRACTICE PROGRAMME PACKING LINE SAVINGS IN THE FOOD AND DRINK INDUSTRY GOOD PRACTICE: Proven technology and techniques for profitable environmental improvement