Causes and Countermeasures of side crack of the ho

Reasons and Countermeasures for bottle washing machine side crack

the packaging cost of beer accounts for a large proportion in the cost of finished products that reduce the emission of 50%~80%2 carbon oxide at the same time. The proportion of different packaging forms and packaging containers may vary, but on average, it still reaches about 60%. In breweries, the packaging cost of glass bottled beer also accounts for a large proportion of the product cost. In the production process of bottled beer packaging, if recycled bottles are used, the glass bottle consumption will generally reach about 1%, which may be as high as 3% in some distilleries with low management level. However, the consumption of glass bottles in the production process can be improved to a certain extent, so reducing the consumption of glass bottles has become one of the focuses of energy conservation and consumption reduction in breweries. In order to reduce the bottle breakage rate, many breweries have adopted various methods and measures. The total bottle breakage rate of some breweries has been reduced to 0.3%, close to the international advanced level

our company has always regarded the broken bottle rate as an important economic assessment index of the packaging workshop in the packaging cost assessment of the past two decades. Through the efforts of technicians and employees for many years, certain results have been achieved, and the bottle breaking rate is basically maintained at about 0.3% - 0.4%. However, some changes have taken place since 1997. With the needs of market development, the diversification of beer glass bottle types began to appear in the late 1990s: different brands or different product units developed their own special bottles, which are not only different in capacity, but also different in diameter, height and shape. The same beer packaging production line may need to produce products with different bottle types until normal. In the actual production operation, different styles of special bottles and ordinary bottles will enter the production line. Without changing the bottle washing process, we found that the bottle breaking rate of the production line is gradually increasing

from the statistics, we also found that the rise of broken bottles mainly occurred in the bottle washing machine. Therefore, we classify and analyze the broken bottles of the bottle washing machine, and find an obvious phenomenon: after the glass bottles are washed by the bottle washing machine, a small gap will appear in the annular part of the bottle mouth of some bottles. This gap will make the product after filling and capping have the potential hidden danger of air leakage, so this kind of glass bottle can no longer be used and must be treated as a broken bottle. We define a new term for this kind of glass bottle, called "side collapse bottle". This kind of side broken mouth bottle increases with the increase of the types of bottles used. And it is more obvious when the bottle box of the bottle washer is made of iron. For example, the bottle box of the bottle washing machine of our company's 1 packaging production line is made of iron; At the same time, line 1 is responsible for the production of products with different bottle types in our factory, and its side collapse rate is significantly higher than that of other production lines

in order to solve the problem of side collapse of the above 1 bottle line, we have discussed with the original manufacturer of bottle washing machine in Germany and relevant technical experts, but they have failed to put forward effective methods and improvement measures to reduce the side collapse rate of glass bottles. Therefore, while relying on external forces, biodegradable plastics and other rubber and plastic products industry, we have also been organizing our technical personnel to tackle key problems. After several years of efforts, we have now mastered the causes of this side collapse phenomenon, and taken corresponding countermeasures to significantly reduce the side collapse rate. Here, we will share our experience with you

I. what is side collapse?

a small piece of glass falls off at the upper or lower part of the bottle mouth ring of the glass bottle, resulting in the quality defect of the bottle mouth

second, the reasons for the side collapse of glass bottles

after continuous observation and test, we found the reasons for the side collapse of glass bottles in the bottle washing machine

1. Due to the diversity of HTML document generation sources, the direct cause of the side collapse of the glass bottle is

the glass bottle enters the bottle box of the bottle washer and moves with the main chain. When the bottom of the glass bottle contacts the bottom plate of the bottle washer or is in the transition position of turning, it will be affected by the following external forces:

the friction between the bottom of the glass bottle and the bottom plate of the bottle washer or the transition plate of turning

the resistance of the bottom of the glass bottle when it contacts a hard object will make the glass bottle produce a sudden jumping force

when the glass bottle is in the position of turning transition and hanging in the air, a falling gravity will appear

due to the partial gap between the glass bottle and the bottle box, the above three forces will make the glass bottle constantly collide with the bottle box during the movement of the bottle box of the bottle washing machine, and the force opportunity of the bottle mouth will increase. If the bottle box is made of relatively hard iron material, and the bottle mouth of the glass bottle just collides with the hydrophobic notch of the bottle box mouth, the side collapse phenomenon will occur when the force on the unit area of the bottle mouth reaches the limit

2. The root cause of side crack of glass bottle

the above is the direct cause of observation. After analysis and deliberation, we find the root cause of side crack of glass bottle

(1) the distance between the running track of the main chain of the bottle washing machine and the bottom plate of the bottle washing machine or the turning transition position is too large, so that the distance between the bottle box and the bottom plate of the bottle washing machine is too large. During the movement of the glass bottle with the bottle box, the moving space of the glass bottle increases (especially the shorter bottle), so the force of the glass bottle colliding with it increases during the movement of the bottle box, resulting in side collapse. This theory has also been verified in the statistical analysis of our actual production data

(2) the bottom plate or transition plate of the bottle washing machine is uneven. When the glass bottle moves with the bottle box, it will jump up when it meets the hard object on the bottom plate. This is easy to make the glass bottle mouth collide with the metal bottle box, forming a side collapse

(3) the transition arc of the turning position between the tank body and the tank body or inside the tank body of the bottle washing machine is too rapid, causing the bottle mouth to collide violently with the metal bottle box

III. countermeasures and measures to improve and reduce side chipping

we have found the root cause of side chipping of glass bottles in the bottle washing machine. For this reason, the more direct solution is to change the bottle box from iron material to plastic material. Although this plan is simple and direct, the cost of transformation is very high, almost one-third of the price of buying a new bottle washer. Therefore, we decided to adopt the method of improving the equipment structure to achieve the same purpose and effect. The improvement measures we have taken are as follows:

1 Redesign the distance and track between the main chain guide rail and the bottom plate of the bottle washing machine. Reduce the original distance from 125mm to 108mm, reduce the gap between the glass bottle and the bottle box, and keep the trajectory of the bottle box consistent with the distance from the base plate. Thus, in the washing process, the bottle mouth of the glass bottle with the shortest position is located in the middle of the bottle box mouth, avoiding the root of the bottle box mouth (that is, the position of the opening notch of the bottle box mouth) and avoiding violent collision between the two. On the other hand, the mouth of the glass bottle with the highest position will not top the mouth of the bottle box during the washing process (the glass bottles used by our company have three heights, ranging from 240mm to 270mm)

2. Redesign and manufacture the main chain guide rail of the bottle washing machine to improve the situation that the transition arc position in the tank body and between the tank bodies is too rapid

3. Flatten or remake the bottom plate of the bottle washing machine, eliminate the uneven phenomenon, and keep the glass bottle running smoothly

4. Control the bottle washing process and the sanitation of the washing machine, so that the temperature difference of each washing tank during the operation of the bottle washing machine is kept within the allowable range (generally not greater than 25 ℃). In addition, the broken bottles and broken glass in the bottle washing machine should be cleaned in time to make the movement of glass bottles in the bottle washing machine more stable

IV. effect after the implementation of action measures

in view of the above analysis and the implementation plan formulated, we first transformed the bottle washing machine a ~ d (blue part) section of 1 packaging production line to achieve the improvement effect

the above improvement measures are feasible and effective from the perspective of the decreasing range of lateral collapse. If the entire movement track inside the bottle washing machine is modified (including the remaining unmodified part in red in Figure 12), we can completely solve the phenomenon of glass bottle side collapse in the bottle washing machine

source: Guangzhou Shengli Beer Co., Ltd