Taking inspections to the next level

Robo-QCS is a single solution that can automatically monitor your beverage line performances [CP and CPK], improving and automating your quality control process.

CARRYING OUT SEVERAL nondestructive quality control operations at any one-time during production can optimise the production process and prevent non-conformities, which ensures complete product quality. These are some of the results that can be obtained by inserting an automatic robotic system in line.

The system allows monitoring of the efficiency of the whole filling and capping process in real-time. Its advanced data analysis system crosses all acquired values by its stations and from all other installed inspectors allowing the optimisation of line performance and the product’s quality protection. Reduce your costs through predictive maintenance, manage claims thanks to the historical database and plan production improvements using all the stored information with the advantages of improved productivity and quality. Let’s analyse its full potential below:

WHICH NON-DESTRUCTIVE INSPECTIONS CAN BE CARRIED OUT SIMULTANEOUSLY IN A SINGLE ANALYSIS PLATFORM?

Usually, four types of controls or measurements are identified:

• Weight and volume control.

• Checking correct cap application by measuring torque and application angle.

• Measuring the concentration of gases in the headspace (e.g. CO2, N2, etc.)

• Measuring micro leaks between cap and preform.

HOW CAN THESE INSPECTIONS BE DONE SIMULTANEOUSLY?

A robotic arm picks up samples from the production line and inspects them in an automatic analysis station through nondestructive tests. These controls are required by law or necessary to optimise and satisfy internal processes and procedures. Compliant samples are automatically reinserted in line. It is not necessary to change the production speed of the line and there is no operator intervention.

HOW IS THE LINE EFFICIENCY IMPROVED?

The inspections and quality controls on the samples are performed in real-time in the automatic analysis station next to the production line and this replaces the manual checks carried out on the line.

The data is automatically correlated to a production date and time, and aligned with the efficiency of the filler and the correct operation of the capper. It is, therefore, possible to recalibrate the equipment instantly in the event of deviation from specifications, monitor trends over time and plan targeted and punctual preventive maintenance.

The ROBO-QCS

With ROBO-QCS there is a real-time level control preventing large non-compliant productions.

The controls of the ROBO-QCS allows for:

• Recalibrating filling valves that do not fill properly - On average, the standard procedure involves a random manual weighing of 20 bottles every 4 hours. If a deviation occurs to the filling valve during this time, overfilled bottles are produced. With ROBO-QCS, there is a real-time level control preventing large non-compliant productions. The correlation of the sampled bottles to the specific filling valve provides additional important information enabling other controls and dedicated adjustment. This is extremely important information that with manual sampling is difficult to have.

• Evaluating the correct application of the cap - The standard manual procedure involves checking the torque on a random sampling of 20 bottles every 4 hours. With ROBO-QCS, continuous checks for the correct application of the cap through removal torque and application angle. Automation allows specific monitoring of the individual capping heads without the need for operator intervention and eliminating the randomness of sampling as per the filling valves.

• Checking the filler and the capper at the same time with immediate possibility of maintenance - With ROBO-QCS, it is possible to control two or more parameters at once. This means being able to set the equipment very close to the correct setpoint, allowing for planned interventions and maintenance.

• Reducing the production loss - The checks carried out with ROBO-QCS are all non-destructive and therefore the samples used for the inspections can be placed back into the packaging line.

• Digitising the data - ROBO-QCS produces date and time reports that can be shared digitally and used retrospectively during an audit to optimise internal processes or recover data from a specific batch.

• No variability due to operator when making measurements - With ROBO-QCS, no operator is needed on the line. Inspections and records take place automatically, eliminating the possible influences of manual verification. •

TracePack - www.tracepack.co.za