Recent Innovative Engineering and Installation Successes
Glass line Capabilities
Project Summary
CtR recently expanded on existing glass and dairy beverage container expertise with the design, procurement, installation and start-up of a new turn-key best-in-class packaging production line for our client. The project included the expansion of the existing process systems to keep pace with the added facility production capacity.
The complete project included analysis and procurement of all equipment including the product sterilization process. A best-in-class approach was used for all machinery centers that ensured all equipment and integration was the best possible solution for the respective areas of production and packaging.
The line has the capability to produce two different sized products in two different secondary packaging configurations, using corrugate trays with film, and two different pallet configurations. The line has future capacity for additional products and packaging. A complete inspection system was designed and installed to maintain quality for the products.
Sustainability
Project Summary
A recent CtR project targeted reducing water waste in a beverage manufacturing facility. Our customer wanted to reclaim water in two different process areas that had previously been dumped to drain. The goal of this sustainability project was twofold: to lower utility costs through reduced water usage, and make this customer a more responsible global citizen through conservation of natural resources.
Excess drain water was identified in two areas: Rinse water from two PET bottle rinsers, and filler water from a dedicated water line. We captured, deozonated, filtered through reverse osmosis and stored this water in a holding tank, before it was recirculated and reused for new water and beverage production. (In other similar projects, we’ve used this reclaimed water in the operations of ammonia systems, cooling towers, and cleaning systems.)
The project scope included new process piping, new sump tanks and process pumps, in addition to controls programming.
The total water saved as a result of this project was approximately 5 million gallons per year.
Line Efficiency Improvements
Project Summary
CtR provides audits and efficiency studies that can help you achieve your production goals with existing production equipment.
A recent project involved an engineering audit and subsequent case conveyor upgrades on a can line at a brewery. The client desired to increase the overall efficiency of the line by increasing the case conveyor speeds, which in turn would allow for greater packaging flexibility between their two fillers and two packaging legs. Upon completion, one packaging leg will have the capability of handling the entire throughput of both fillers in operation. Therefore, changeover between packing legs will not infringe on production time.
Cost effective improvements for the mechanical areas were developed that included replacing conveyor components as well as complete conveyor sections that appeared to be hindering the operation. A control scheme was developed that could maximize operation once the mechanical obstacles were remedied.
The final results achieved provide increase in productivity by eliminating changeover production lost at the packer.
Documentation
Project Summary
CtR completed a documentation project that established the engineering standards for a major beverage manufacturer. The engineering standards will provide the manufacturer documented guidelines for the selection, operation, and maintenance of production equipment. The client’s expertise and experience with day to day operations was combined with CtR’s broad knowledge to help formulate conditions and design standards that enable a best in class selection of equipment, best maintenance practices, and reduction of after-market costs.
Empty Can System Design which eliminates change parts for multiple container heights and diameters
Project Summary
The client requested an empty can delivery system that would allow for a range of empty can heights and diameters with minimal changeover time to be performed by operators rather than line mechanics, and allow for future can size additions with minimal investment.
Traditional design on the empty can system includes a gravity fed twist fitting style air rinser sized specifically for each can diameter, and an airveyor or cable conveyor delivery system with multiple position air cylinder actuated top covers. In addition an Air combiner provides the flow of cans from mass to single file which also requires precise positioning of the top cover for proper can flow.
CTR designed an empty can system utilizing mat conveyors feeding a Zero-pressure combiner, and a single lane vacuum lowerator that carried the can to a vacuum inverting Air nozzle rinser which holds the can by the base. The can path then levels the vacuum chain at the Filler infeed height and transfers the can to a single lane Airveyor for delivery to the Filler infeed metering worm. Design includes the distance calculations from the rinser to the filler for the accumulation and recovery of single file cans to continuously feed the filler despite slight flow variations of the cans from the Zero-Pressure Combiner. Equipment vendors were sourced from the can manufacturing industry as well as traditional soft drink equipment suppliers and integrated for optimum mechanical design and Sequence of Operation. The system has been proven effective for the required quick change features, as well as efficient delivery of cans to the Filler.
Modular Syrup Room Process System Design
Project Summary
The client requested an efficient modular design that would be applicable in Greenfield sites as well as retrofit into existing syrup rooms. The standardization of components also required development and adherence to a Clean-By-Design Specification to reduce technician time to keep all internal and external surfaces sanitary. The resulting plan view and P&ID diagram with associated install drawings of the vendor components were integrated into a standard design with modular systems. The operator platform, valve matrix skid, tanks farm, and all associated piping was designed for doubling capacity as the business required the addition of another packaging line or two. Control systems were provided with large backbone and PLC capability, with incremental investment required to double or triple capacity.
Heat Recovery of Mold Cooling Process Water
Project Summary
The client requested the heat normally discharged to the atmosphere via the cooling tower exhaust of heat removed from the molds of blow molders be captured and transferred to the water utilized to warm the cold-filled containers.
Through the addition of properly sized and routed supply and return loop piping the recirculating water heated at the discharge of the blow molders is pumped through plate and frame heat exchangers at each warmer to provide BTU transfer to the water sprayed over the cold containers. The process flow was designed to capture the maximum available BTU’s for each warmer and send the water through the cooling tower as a last thermal transfer device thus using available BTU’s first for required warming processes. Steam use has been reduced to start-up and shut-down periods when the heat transfer becomes unbalanced thus saving steam use significantly to heat the water in the warmers.