The hottest pet vial filling line ensures the safe

2022-08-08
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Pet vial filling line ensures Pepsi's safe and high-speed production

the pet vial filling line in Pepsi's new factory can fill five different sizes of bottles at the speed of 1100 bottles per minute. The clean separate sealing room accommodates the flushing/filling/capping system to ensure maximum hygiene

at the end of 2004, the first batch of Pepsi Cola products packed in pet vials were put into operation in the production/distribution plant of Pepsi bottling company listed in North Carolina, the United States. The plant invested US $40million and covered an area of 20000 square feet. The output of the four packaging lines can reach 24million boxes, and it is expected that the production capacity will increase to 30million boxes by 2010. The four lines are: a 12 ounce filling line with 1600 cans per minute, a 1-liter, 2-liter and 3-liter pet filling line with 40 bottles per minute, a filling line for 12, 16, 20 and 24 ounce and 500 ml PET bottles (1100 bottles per minute), and a "bag in box" packaging line with 12 bags per minute

one of the main purposes of Pepsi bottling company to build this new factory is to produce bottled water with Aquafina as the trademark, which is the fastest growing trademark in the Pepsi family. Bottled water is the fastest-growing product in the U.S. beverage industry. This market is very cost sensitive. In order to gain competitiveness, PepsiCo needs its own high-speed production workshop. In addition to Aquafina, other well-known brands produced by this Pepsi factory include billow, Sierra mist, Pepsi light, Lipton fragrant tea, fruitworks, Dr. Pepper, Hawaiian punch, sunkis and nugrape

the new factory features a clean enclosed space designed and manufactured by ICS international. These spaces respectively contain the cleaning, capping and filling systems on the pet line. The enclosed room is designed with epoxy floor, slightly inclined, inclined to a stainless steel drainage tank, and has a complete air quality control system. The walls and ceilings of the enclosed room are insulated sandwich panels, both inside and outside are stainless steel panels, and the middle is filled with polyurethane foam. The enclosed room is a self-supporting structure, using module panels to achieve the shortest installation time and the smallest amount of civil engineering on site. All pipe and conduit openings through the roof and ceiling are properly sealed to ensure the air tightness of the compartment. The cleaning room is equipped with complete lighting, access control, air filtration, air conditioning and air exhaust system

the air filter device maintains the pressure in the enclosed room to prevent external air from entering, and ensures 40 air changes per hour. The filter unit also has a cooling coil to cool the air in summer. The filtration device has three filtration stages: rough filtration, bag filtration and HEPA filtration, and the average air quality achieved is 1000. Normally, the air discharged from the enclosed room is discharged into the surrounding processing plant. However, in order to prevent the air with sugar or ozone from being discharged into the surrounding area of Pepsi factory, ICS company added an air extractor to suck the air out of the enclosed room and transport it outside the factory

Vincent Mitchell, sales manager of ICs, said, "every enclosed room is specially designed to seal the filling system as close as possible. This limits the amount of air near the filling machine, so the air quality can be guaranteed to be the best. This design also allows the operator to stand outside and control the machine."

high speed pet vial filling line

take Pepsi's ongoing production of 16 Ounce surge beverage as an example. The pre labeled bottles provided by Amcor are sent to the automatic destacker on the pallet, with cardboard compartments between each layer. The automatic destacker will raise the pallet one layer at a time, swing it over with a sweeping frame with suction cups, and automatically remove the partition board (the partition board is stacked into a box and returned to the packaging bottle for feeding. In order to facilitate measurement, the threshold is also low). The automatic destacker lifts the bottles up again, and the sweeping rack sweeps the bottles onto the batch conveyor. Sentry equipment company provided the factory with automatic destacker and all conveyors, and also helped PepsiCo complete the layout and control of the packaging line

The bottles of

are transferred in batches to two lanfranchi high-speed automatic palletizers, where the rotating frame stands the bottles up. In order to keep up with the speed of the production line, the factory needs two automatic palletizers. The level sensor in the hopper of the automatic palletizer controls the switch of the transfer elevator to maintain the number of bottles in the hopper. Automatic palletizer improves material handling and reduces human labor

the packaging bottles from two automatic palletizers converge into a row and then spring into the air conveying system holding the bottleneck. The bottle in the conveying system is supported by a rod under the surface of the bottleneck. The air flow in the conveying chamber pushes the packaging bottle forward. The destacking working area includes three destacking machines. This working area is set up to allow two operators to feed containers to the three production lines. Empty bottles are directly transported to the clean enclosed room and the star conveyor wheel of the single block washing machine Filling Machine Capping machine through the air flow conveyor belt. The advantage of using single block design is that only one star conveyor wheel is needed from the washing machine to the filling machine or from the filling machine to the capping machine, which greatly reduces the problem of packaging bottle transfer

the bottle is sent to the chuck of the 108 seat washing machine through the inlet and placed upside down when the device rotates. The purified water is injected into the bottle through the nozzle attached to the chuck, and then flows out as the device continues to rotate. The cleaning solution contains ozone to achieve the best cleaning effect. Then the packaging bottle stands up and is sent out through a conveyor wheel

the isobaric volumetric filling machine used for filling has a total of 144 filling valves. Washing machine and filling machine are provided by Sidel company. Each filling valve is connected to the central liquid tank through a product pipe, and is also connected to the carbon dioxide supplier through two gas pipes. One is used to pressurize the packaging bottle, and the other is used to stabilize the pressure between the liquid tank and the filling valve. When processing non carbonated beverages, the system uses nitrogen instead of carbon dioxide. The horizontal plane in the filling cylinder is basically the same as that in the central tank. By changing the horizontal plane in the central tank, the filling volume for bottles of different sizes can be changed. There is a piston in each hydraulic cylinder to set the exact filling capacity through the external magnetic coupling, with an accuracy of ± 2 ml. This process is controlled from the operation panel

the final product of carbonated soft drinks is filled with a high-speed filling machine. Before filling, it should be cooled to 35~50 degrees Fahrenheit to ensure the amount of carbon dioxide in the product. In order to minimize ammonia in the whole system, save space and improve cooling efficiency, each PepsiCo filling machine is equipped with a stainless steel plate and frame heat exchanger to cool the product from 86 degrees Fahrenheit to the final filling temperature required by the product. After cooling, inject carbon dioxide into the product, and then pour the product into the bottle

every time you change a taste, the pipeline, box and filling machine need to be cleaned and disinfected. Each filling machine has a separate automatic cleaning system, which manages the necessary chemical cleaning products and cleaning cycles to minimize all the time required to clean the whole system and resume operation

bottles are transported from the filling machine to the CSD screw capping machine of arol company through another conveyor wheel. The bottle cap is provided by Alcoa, and the sorting system provided by the packaging system Department of Sidel company classifies the bottle cap and sends it to the capping machine. The bottle cap is loaded into a hopper outside the sealing room, in which there is an almost vertical conveyor belt to send the bottle cap to the top of the sealing room. The bottle cap is clamped in the horizontal splint on the conveyor belt. If the positioning direction is wrong, it will fall back into the hopper. The conveyor belt unloads the bottle cap onto a track, which sends the bottle cap down to the capping machine. The star conveyor picks up the bottle cap from the track and puts it on the capping head, which rotates synchronously above the rotating frame for placing the bottle. When the device rotates, the capping head is lowered and the bottle cap is screwed onto the packaging bottle according to the preset torque. Arol company provided Sidel with the upper cover rotating frame including the cover head and drive wheel, and Sidel was responsible for assembling the whole unit

the capped bottles leave the enclosed room, pass the filtec X-ray filling height detector of industrial dynamics, and then print the shelf life on the anti opening ring of the bottle cap through two vidige excel inkjet machines. The factory has installed two inkjet printers, one of which can be replaced in case of failure, and there is backup. In order to be more secure, the domino laser printer prints the production code and shelf life on the bottle. After numbering, the bottles are transferred to the multi chain plastic belt conveyor, the speed is reduced from 350 feet/minute to 40 feet/minute, and they are stacked again from a single row

carbonated soft drinks do not seriously damage the physical and chemical performance indicators of plastic products; If the cold filling is carried out within the temperature range of 35~50 degrees Fahrenheit, if the bottle body is not heated again after filling and capping, the bottle body will sweat and damage the package. Therefore, the beverage bottle is sent to an in-line heater provided by G.C. Evans, and hot water is poured out from the nozzle above to heat the bottle to the ambient temperature. The heater consists of a 10 foot wide plastic belt that transports bottles into the warehouse in batches under hot water spray. The heater automatically adjusts the water temperature according to the wet bulb thermometer in the warehouse, so as to reduce energy consumption and realize process optimization

multiple packing options

the factory produces more than 250 inventory units, and the products have 40 different flavors and different packaging combinations. The finished product is transferred from the heater to the conveyor, the product is sent to the packaging machine, and the bottles are put into cluster packaging or bulk

a hicone machine carries out 6-bottle packaging of 16 ounce, 24 ounce and 500 ml beverage bottles. The beverage bottles are sent to the hicone machine through two channels. The machine separates every six bottles and puts them on plastic brackets. At first, the plastic support is a continuous piece, which is sent to the big vertical wheel rotating above the bottle in the form of. The vertical wheel covers the six bottles, and then cuts them off to separate the six bottles. The packaging is then distributed to two channels and sent to the continuous action hartness 2650 packaging machine. Every four six bottle packages are put into a reusable plastic crate and sent to PepsiCo's warehouse for distribution. 20oz bulk bottles are shipped directly to the hartness machine and packed in plastic pallets

bottles can also be transferred to a packaging equipment integrating mw7 multi-function packaging machine, TDL tray forming/loading machine and shrink packaging machine, all of which are provided by Douglas machine company. Each of these servo driven machines has a separate control panel, and the intuitive touch screen interface can display production data, maintenance plan and change settings

all kinds of beverage bottles, including 500ml drinking water, 5 00ml carbonated beverages and 12 ounces of drinking water, which should be in accordance with the size specified in the relevant product standards, are sent to the multi-function packaging machine, and 6 or 12 bottles are wrapped in a overprinted film. This is a dual process equipment, which can pack two groups of bottles in parallel at the same time. Bottles are fed into the machine in batches and divided into 6 bottles or 12 bottles by the leadless measurement system. These groups of bottles then enter the packaging area. The film is wrapped around a set of bottles and then heated to shrink the tunnel

4 6-bottle packages or 2 12 bottle packages enter the tray forming machine/packing machine. The machine forms a tray with paperboard raw materials, pushes the packed package into the tray, and then seals it with Nordson's sealing system. Some 500ml drink bottles and all 20 and 24 ounce drink bottles can be transported directly to the tray through this multi-function packaging machine

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