Description

INC8 Line

  • 250 ml @16,000 bph
  • 300 ml @16,000 bph

INPAKT

Sales Person: Alexi Christie

Tel: +27 81 373 9154

Email: alexi@inpaktgroup.co.za

 

1 – LINE DESIGN

Design & Line Parameters

Basic format – Product 0.25 L  and 0.30 L – CSD
Leading Machine Er-miraBLC 8
Nominal line speed* 16.000 bph
Line efficiency** 90%
Bottle Capacity Design line speed Pallet Type
Second format 0.5 L 16,000 bph

3×4 film only

6×4 film only

1200 x 800
Basic format 1.5 L 10,000 bph

3×2 film only

 

1200 x 800

The mentioned values are for information only and is subject to change

The presented above values are indicative and subject to confirmation after receiving the definitive drawing of the container, the definitive weight of the preforms.
The final position of equipment, chiller, compressor shall be determined according to the customer warehouse measurement and his building limitation
Conveyors and line design is subject to change according to final layout . Any modification requested by Purchaser or additional conveyors will be priced.

2 – ENVIROMENTAL CONDITIONS

Description                                             Criteria Standard Value
Outdoor temperature Min (°C) +5
Max (°C) +40
Indoor temperature Min (°C) 15
Max (°C) 30
Altitude Max ( above sea level) 300
humidity Min (%) 30   min 30% – max 70%.
Max (%) 90
Chiller location In Room
Electrical Power Voltage (V) 400
Tolerance  (%) + /- 10
Frequency (Hz) 50
Distribution System
Phases 3 PH

3 – CONTAINER FEATURES

Container name Format 1 Format 2
 Container
Product CSD CSD
Container 0.5 2
Material PCO 1881  PCO 1881
Drawing TBD TBD
Preform drawing TBD TBD
Neck Type PCO PCO
Shape Round (stright /wavey / standard ribs ) Round (stright /wavey / standard ribs)
Diameter (mm) Ø=68mm Ø=88mm
Bottom  type Flat Flat
Material weight (g)    TBD    TBD
Filling Tempreature (°C) 7-15 7-15
Cap
Drawing TBD TBD
Type Screw Flat Cap Screw Flat Cap
Neck finish typ PCO 1881 PCO 1881
Material Plastic Plastic
Label
Drawing TBD TBD
Material OPP OPP
Label type Wrap around – roll fed Wraparound – roll fed
Packaging
Type Only film Only film
Configuration 3×4 3×4
Pallet type 1200×800 1200×800

4 – EQUIPMENT TECHNICAL DESCRIPTION

Rotary INC8 Blowing Filling Capping
MODEL 8-INP44-8

8 cavity rotary stretch-blow moulder
44 electro-pneumatic filling valve rotary
8 head rotary capper, for screw caps

Picture is only for clarification purposes.

General Description

Integrated system and Perfect combination of stretch blow moulding, filling and capping in a single block
Stretch blowing unit is equipped with a heating module and high efficiency reflective panels to ensure uniform heat distribution on the preform.
filling area is entirely made of stainless steel and glass.
Neck handling system, and transmission system by wheels.

Preform heating (heating oven)

Picture is only for Clarification purposes.

  • Consisting of a horizontal linear heating module which ensure very precise heating process with low electrical consumption
  • Optimize ventilation operations
  • Infrared lamps grouped in various sections and individually controlled.
  • Dedusting system
  • Detect and eject incorrectly loaded preforms, which located before the oven inlet
  • Accurate preform transmission from the oven to the mold
  • A collecting case (bin) for ejected preforms, can able of emptying during machine operation

Blow station

Picture is only for Clarification purposes.

  • The machine‘s Rigid body construction provides stable operation and longer life
  • Elimination of conveyors between the blow-moulder and the filler
  • The direct transfer of the bottles from the stretch blow moulder to the filler and capper is provided .
  • Easy access to the machine components , cleaning easier
  • Reduce noise , no vibration , quieter bloc
  • Dedicated to all bottles belongs to the range 0,2 lt -2 lt
  • Wide opening doors for easy access to the machine components for maintenance and quick-changeover
  • Central rotating wheel for blowing station
  • NO Cam system commanding mold unit , Fully PLC controlled ,Fully electric
  • Patented opening-closing system for mould carriers controlled by servo
  • Servo controlled stretching system
  • Auto-locking system for mould
  • Quick-locking system for mould carriers
  • Synchronously closed + lock system
  • Aluminum mould ‘s holders made of iron
  • Fast with no vibration
  • Controlled pneumatic mold compensation using solenoid valves
  • Air recycling system
  • Tracking system for each cavity
  • Solenoid assembly for air distribution in the blowing mold with low consumption
  • Lubrication; An automatic pump to grease all the points
  • user friendly interface navigation system for machine operation, maintenance, mechanical setting and process parameter
  • Industrial PC system is electronically controlled.
  • Industrial PC has Ethernet port, so the process has the ability to intervene immediately to the problems on the internet
  • All process parameters can be set via the Industrial PC
  • A temperature control system of the oven
  • Pre-blowing process apply by electronic servo-controlled stretching unit
  • Electronic servo controlled clamp and preform transfer group provide transfer process without wastage
  • Oven wheel system which has48 mm pitch achieve 10% additional power saving
  • Independent servo control implements on the transfer wheels units of
  • Perform & bottles to provide quick adjustment via its easily PC
  • Fully electrically , No Cam system commanding mould Unit
  • Process monitoring system is implement for each cavity of the mold depending on the pressure -time graphical diagram
  • Advanced HMI electrical control
  • Cooling system for mold
  • Air recovery system provides up to 25% saving
  • An ejection system for defective bottles
  • A machine emergency stop disk brake
  • A manual drive for machine adjustment and maintenance
  • Quick format change over
  • Reduction of format change-overtimes, and extremely less maintenance.

Control console

  • Consisting of navigation system for machine operation, maintenance, mechanical setting and process parameter set-up
  • Machine operator intervention and it ‘s follow-up is comfortable through 15 “” color TFT touchscreen
  • Multi languages.

Octabin Tilting Unit

Characteristics                                           Type
Installed power 240 KW
Consumption 83 KW
Voltage 220 – 380 V 3 phase 50 Hz Variable Frequency Driver
Machine Control PLC
 Low Pressure air consumption  2 m³/minute- 8 Bar
 High pressure air consumption  23 m³/ minute -30 Bar
 Cooling Water  110.000  kcal/hour 5-7˚C
 Cooling Water Pump  60.000lt/hour ∆P=3 Bar. ( ∆P=Pin-Pout)
Characteristics                                           Type
 Servo Motor

 

 

 BOSCH REXROTH – KOLLMORGEN

 

 Drivers  BOSCH REXROTH – KOLLMORGEN – OMRON

 

 PLC  BOSCH REXROTH – KOLLMORGEN – OMRON
 Bearings ROLLEX  – FAG – SKF – ORS
 40 BAR Valves

 

 

 

INPAKT
 Pneumatic SMC – FESTO – MAC
Gear Box LİMİNG – APEX
 Mold Material ALÜMİNYUM
 Electrical component  WEIDMULLER – EATON – OMRON

 

 Sensör  TURCK  WENGLOR – Sick

 

Machine frame SS

Filling station

Is a fully automatic rotary filling/capping bloc, it is integrated with blow moulding machine which eliminate rinsing and air conveyor.

Picture is only for Clarification purposes.

  • Completely automatic rotary filler specifically designed and manufactured for high speed lines
  • Prevent overflow
  • Very precise
  • Easy cleaning (internal, external)
  • Base frame in AISI 304 stainless steel and self-draining slopes to avoid water retention
  • All the surfaces which contact with the product is AISI316 stainless steel
  • No bottle –no filling system
  • Hepa filter with fully enclosed cover
  • Individually controlled from the operator panel
  • A sensor detects the presence of the bottle before entering the filler
  • Quick format changeover
  • Stainless steel necking star for bottle transfer
  • Bottle neck handling
  • Star-wheels for bottle transfer
  • Automatically speed controlled by the PLC
  • Pre-arranged for cip with dummy bottles
  • Manual dummy bottles
  • Guaranteed hygiene: over pressure with Class 10,000 filtered air on the transfer table prevents contamination of the outside of the bottle

Any other configuration can be separately quoted as options.

Electro pneumatic controlled isobaric filling

  • The container and the filling head ll be in contact.
  • To create pressure in the bottle and equalized the condition of tank pressure.
  • Faster and efficient gas release.
  • All the operating phases (filling, gas release, etc.) are run automatically.
  • Very precise gas release phase.
  • Reduces the risk of foaming and liquid overflowing.
Characteristics                                           Type
valve
Filling principle Electro pneumatic controlled isobaric filling

 

Container handling By Neck
Container transfer starwheel
Construction
Frame AISI304 stainless steel welded structure
Draining Self draining sloped surface
Tank AISI316L stainless steel
Metal parts in contact with product AISI316L stainless steel
Plastic parts in contact with product Food gradable
Electric cabinet
cabinet stainless steel
Characteristics                                           Type
Voltage 220 – 380 V 3 phase 50 Hz Variable Frequency Driver
Machine Control PLC
Speed Control By PLC
Characteristics                                           Type
 Motor  GAMAK – ELKMOTOR – BOSCH REXROTH KOLLMORGEN – OMRON
 valve  INPAKT
 Reductor  YILMAZ (TURKEY)
 Gear Box  LİMİNG – APEX
AUTOMATION AND CONTROL SYSTEM
 PLC  BOSCH REXROTH – KOLLMORGEN – OMRON
 Pneumatics  SMC – FESTO – MAC
 Electrical components  Weidmüller – Eaton -Omron

 

 Sensors  Turck  Wenglor – Sick

 

 Filter HEPA-14

CAPPING MODULE ( CAPPER )

Picture is only for Clarification purposes.

For one specific type and format of cap, Any other configuration and its equipment are separate and quoted as options

Cap elevating and orienting system

components & operation:

  • Cap feeding system (water-fall feeding system)
  • Cap hopper
  • Elevating
  • Orienting system
  • Discharge
  • Cap chute
  • Capping heads are equipped with chucks , with magnetic clutch to adjust the torque
  • No bottle – no cap system

The caps are transferred to a pick and place device through channel (chute );The capping head moves downward to the bottle and applies the cap.

  • Neck handling – for PET
  • Stainless steel support to hold the container during capp
  • Bottle presence sensor
  • Caps feeding system placed outside the machine
  • A Pick and Place device to transfer caps to the closing head
  • No bottle – no cap mechanism
  • Caps are manually loaded into the hopper ( top cover )
  • Basically for one specific type and format of cap
  • For any other configuration and its equipment are separate and quoted as options
  • UV lamps provided for sterilization caps.

Handling

  • Container handling by the neck
  • Container released on an outfeed conveyor with adjustable height system
Characteristics                                           Type
Frame AISI 304 Stainless steel
Capping heads material AISI 304 Stainless steel
Hopper AISI 304 Stainless steel
Pick and Place star-wheel material AISI 304 Stainless steel

Ancillary equipment capacity depending on the country specifications (altitude, temperature, humidity etc.)
Auxiliary parts are not included to the offer.

ANCILLARY EQUIPMENT

High and Low-Pressure Air Systems
Chiller
The final position for the chiller and HP compressor shall be determined according to site measurements
(max 10 m- 15m from blow molder)

Quality of Cooling Water and Distribution Circuits:

Parameters Value
Ph 6.5 < pH < 8
TH (Total Hardness)*  TH < 5 °F – 50 mg/L                                                TH < 35 °F if chemical treatment)
TA (Simple Alkalinity) TA < 40 °F – 400 mg/L
TAC (Total Alkalinity) TA < 40 °F – 400 mg/L
Ca2+ mg/L (the lowest possible)
Mg2+ mg/L (the lowest possible)
Fe2+ Fe2+ < 3 mg/L
Mn2+ mg/L
CO3H – (Bicarbonates) mg/L
Cl (Chloride) Cl < 2.000 mg/L (the lowest possible)
SO42– (Sulfates) SO4 < 250 mg/L
MEST (Total Suspended Solids) MEST < 100 mg/L
FI (Clogging Capacity)** FI < 3
Organic Fraction mg/L
Mineral Fraction mg/L
Residue heat 110 °C mg/L

Minimum volume of water required for analysis=1.5 L
Characteristics
The water circuit must be a closed circuit.
Fit an active 20 μm nominal filter (50 μm absolute) at the machine in let in order to project the machine against their lease of solid particles from the piping or accidental pollution from other machines on the line.

Quality of Air
The air provided by the buyer will comply with quality as below :

Quality of Air
Residual Dust Residual Water Residual Oil
ɥm mg/m3 DTP[C] g/m3 mg/m3
0,1 0,1 -70 0,003 0,01

BOTTLE DRYER

Picture is only for Clarification purposes.

For PET and glass bottles

  • Dryer module
  • Blow-drying of containers
  • Low-maintenance

Configuration according to:

  • Bottle drawings
  • Production speeds

LINEAR OPP LABELLER – SOLM

Picture is only for illustration purposes and not conditionally matching supplied machine.

Linear labeling machine is able to apply wrap around paper label on the body of PET bottles via hot glue technology.

DESCRIPTION
Type SOLM

Automatic Linear roll-fed hot glue labeling machine for applying complete wrap-around roll-fed labels to plastic containers

  • Linear design for easier handling
  • Compact design enables the operator to control all labelling processes
  • Simple change-over and maintenance procedures
  • Less adjustment
  • Easy settings of the labels transfer drum parameters
  • Easy settings of the labels cutting parameters
  • Adjustments via HMI
  • Roll-stand
  • Feed roller
  • Cutting module
  • Integrated HMI for all operations, including labels registration/cutting
  • Transfer vacuum drum
  • Hot melt glue application module.
Characteristics                                           Type
 PLC  BOSCH REXROTH – KOLLMORGEN – OMRON
 SERVO  BOSCH REXROTH – KOLLMORGEN – OMRON
 Electrical component  WEIDMULLER  – EATON – OMRON

 

Eaton

Omron

 Sensors  TURCK WENGLOR – SICK

 

 PNEUMATIC SMC – FESTO – MAC
 REDECTOR LİMİNG – APEX
 BEARING FAG – SKF – ORS
 Voltage  220 – 380 V 3 phase 50 Hz
 Control Voltage  24 V
 Istallation Power  15 KW
 Speed Control  SERVO
 Machine Control  PLC
 Label Type  O.P.P., P.E.
 Label Feeding Application  From rolls
 Glue Type  Hot Melt
 Ambient Temperature  5-35 ºC

Shrink Wrapping Machine Overlap (One Way)

Picture is only for illustration purposes and not conditionally matching supplied machine.

Overlap System Fully Automatic Shrink Packaging Machine with PLC control system, LCD touch screen, 6 servo motors and 8 different programs. There is a 6-channel bottle dispensing unit in the feeding unit of the machine. Horizontal and vertical products coming from the speed-controlled feeding conveyor are grouped in desired quantities. The automatically incoming grouped products are wrapped in automatically fed (PE) polyethylene foils with the help of conveyor belts and the process is carried out with the latest technology overlap system.

Products wrapped in polyethylene foils are fed into the Shrink tunnel with a speed-controlled conveyor and shrinked.

PREMIX SENS MIX

Picture is only for Clarification purposes.

Fully automatic blending and carbonating
System complete system for preparing carbonated soft drinks
mixing a syrup with deaerated water and then carbonation

Process phases

  • Water deaeration
  • Dosage and mixing of the water & syrup
  • Carbonation

Plc control
Advanced flow meter technology for mixing and carbonation
Water deaeration by vacuum pump
Complete product receipt management
Correction option of syrup brix function

Technical Data :
Designed for 7, 10 , 15 and 30 m³/h
Maximum Brix: 30% (Brix: Syrup or solid solution ratio in the final product)
Water inlet temp 15 c
Syrup inlet temp 25 c
max carbonation temp 12-15 c
Co2 content 8.8 – 11 g/l
Chiller not included

Automatic classic Palletizing & Stretch Wrapping Machine

Picture is only for illustration purposes and not conditionally matching supplied machine.

Technical Details
Model EP 100
Pallet dimensions Euro pallets     800 x 1200 mm

Local pallets  1000 x 1200 mm

Capacity 2000 Packet/ hour, 24.000 – 34.000 bottle / hour
Full pallet height 0,5 lt – 8 fold – 1870 mm
Pallet height 150 mm
Voltage 220 – 380 V 3 phase 50 Hz
Control Voltage 24 V
Control SERVO,PLC
Power Consumption 6 kW
Body Weight 5.000 kg.
Body Dimensions 7800 mm x 8650 mm x 4770 mm
Body Material St42- 37 Fe, DTM 7025** paint

Stretch Wrapping Machine

Picture is only for illustration purposes and not conditionally matching supplied machine.

  • High performance rotating arm machine for wrapping pallets with stretch film
  • Reliable, robust construction
  • Flexibility on the production, products and layout
  • Rotating arm pallet wrapper
  • Driven rollers electronically controlled
  • Photocell detection
  • Base frame
  • User Interface
  • Pallet lifting system
  • Stretch finishing, cutting, gluing system
  • Quick stretch changing system
  • Safety control system
  • Safety barriers
Characteristics                                           Type
 Servo Motor

 

 

 BOSCH REXROTH – KOLLMORGEN

 

 Drivers  BOSCH REXROTH – KOLLMORGEN – OMRON

 

 PLC  BOSCH REXROTH – KOLLMORGEN – OMRON
 Bearings FAG – SKF – ORS
 Pneumatic SMC – FESTO
Gear Box LİMİNG – APEX
 Electrical component  WEIDMULLER – EATON – OMRON

 

 Sensör  TURCK  WENGLOR – Sick

 

CONVEYORS

Set of stainless steel bottle conveyor as per layout
Frame, supports, legs and components made of stainless steel AISI 304
wide range of belts , curved Frame , Transfer Frame

Characteristics                                           Type
Belt

 

REXNORD – KAZİAN
Gear YILMAZ REDÜKTÖR
Invertor

 

 

OMRON – ABB
 Bearings FAG – SKF – ORS

EQUIPMENT LIST & PRICES

1 ROTARY STRECH BLOW MOULDING – FILLING – CAPPING

Rotary Stretch 8

 
Qt
Rotary Stretch-blow moulding INC 8

Rotary 8-INP44-8

Heating module : linear over with infrared heating technology

Hot air extraction : Oven exhaust hood

 

Preform Feeder (orienter ): provides the stretch blow moulder with preforms and can be adjusted to the preform sizes.

Pet preform dumper (tilter)

Pet preform elevator

feed rail.

Platform with stairs

 

High-pressure compressed air filtration : using a 0.01 µm fine filter.

Air recovery system: Air recycling system recovering a part of the blowing air and reusing this air for the preblow

 

Automatic lubrication (food gradable grease) system including pump and plastic pipes

 

Protection cover with air filtration unit

 

Faulty containers are rejected within the machine

Fualty heated preform are rejected within the machine

Mould change: manual mould quick change without tools

For base change there is pneumatic button

(change over time 60 min )

 

1 INCLUDED
Main electrical cabinet  in AISI304

Main electrical cabinet air conditioning system

internal lighting

 

1 INCLUDED
HMI : ENGLISH 1 INCLUDED
Aluminium moulds (0.5 lt ) 1 INCLUDED
Aluminium moulds (1,5 lt ) INCLUDED
24 V UPS for Automation group 1 INCLUDED
Automatic CSD Filling-Capping

 

Electro pneumatic valve Control System

 

Simple structure and economical in service and maintenance

Hygienic Design

Product tank in stainless steel AISI 316

Parts in continuous contact with product (tank, filling valves, piping)  in S/S AISI 316

No bottle No filling

Fill level determination : vent tube

Full automatic operation plc controlled

Bottle stopping mechanism

Equipped with photocells in inlet and out let of the machine

Automatic product feed equipped with sensor to control the level in the product tank

Drain channels meet in one point

Rotary Capper

Screw capper 14 head

Caps feeder (water-fall feeding )

Cap elevator

Cap Sorter  AISI304 SS

Cap Channel  AISI304 SS

Cap ejection

UV lamps for Cap feeding system

No bottle No capping

 

Manual operated CIP dummy bottles

(CIP up to 90 degree)

Hepa filter for positive pressure

Lubrication system (top capper , bearings , filler , rinser  ) manually operated.

Pneumatic 5 micron filter

24 V UPS

Industrial AC : electrical cabinet air conditioning system

 

1 INCLUDED

 

2  PREMIX 20 TON  
Fully automatic Blending and carbonating

three modules deaeration, dosing and carbonation

different sizes with variable outputs

from 7 ton to 20 ton

 

electronic flow control valves

 

·         syrup / water mixing ratio  1/3 up to 1/5

·         brix accuracy : 0.05 – 0.03 brix

·         CO2 mixing ratio : 8.8 lt – 11 gr / lt

·         Max carbonation temp 12-15 c

 

The carbonation temperature of 15 C is for a maximum of 8.8 gr/L, the mixing ratio should be specified by the customer since higher chiller will be needed for higher ratio CO2 mixture.

 

 

Deaeration

horizontal deaeration tank the water feed is done by set of nozzles and the deaeration using vacuum process for the purpose

 

Dosing module

Buffer tank equipped with level sensor

Top product quality  due to product homogenisation by

2 static mixer (2 stage )with flow meter and proportional valves

 

Carbonation module :

Venturi mixer for efficient and consistent carbonation

 

24 V UPS

Industrial AC : electrical cabinet air conditioning system

1 INCLUDED
3 OPP OLM-SRV LABELLER   
Linear Roll Fed labelling for cylindrical container

Roll-stand, Feed roller, Cutting module

Transfer vacuum drum

Hot melt glue application module

1 INCLUDED
3 BOTTLE DRYER    4
FULL BOTTLES DRYERS to remove residual from the outsides surfaces of the containers with air INCLUDED