Beverage Filling Line

Problem:
Finished bottled products are weighed for fill accuracy. Products that are unacceptable are expelled from the line into a refuse bin automatically. The plant manager determined a 0.34% scrap rate was unacceptable. Due to distance between operators, adjustments on the filling line were taking too long to make.

Solution:
Given that LED Displays were placed in strategic locations within the control room, the employees were able to see changing trends in filling rates in real-time. By proactively making adjustments relevant to the trend based on reject rates, the filling lines lowered their scrap rates from 0.34% to less than 0.25%.

Data Source:
Fill levels, rates and rejects are collected via the line PLC. The data is monitored on a PLC, logged and analyzed. Actual reject data is sent to the displays in real-time along with commands to control display colors for certain reject levels.

ROI:
Savings were calculated to be approximately $500/day after installation. System costs were paid for in less than 10 days.

Be sure to contact us today to see how we can provide the right service for your needs.