Filler/Capper RCM

1) To fill 530g, 480, 275, and 500g jars

to specified levels and weights and cap at
100 to 220 JPM.
1a Jars do not infeed
1A1 Fallen jars
1A2 Fallen jar detector fails closed
1A3 Infeed conveyor motor /gearbox/control fails
1A4 Infeed conveyor drive fails
1A5 Infeed conveyor belt fails
1A6 Pneumatic failure of jar stop
1A7 One of the sensors fails, S7, S8, S4, 14B4,No
caps in conveyor or no caps in chute
1A8 Incorrect size change
1A9 Filler bowl drive motor/gearbox fails
1A10 Filler bowl drive train fails
2b Jars fail to fill
1B1Jar infeed starwheel sensor fails
1B2 Timing sensor fails
1B3 Pneumatic failure of trip cam
1B4 Trip cam pivot pin fails
1B5 Incorrectly valves fitted
1B6 Valve roller/pin fails
1B7 Valve seizes due to lack of lubrication
1B8 Jar gripper broken
3c Jars filled at wrong temperature
1C1 Product sensor fails
1C2 Product temperature set incorrectly
1C3 Manual bypass operated
4d Jars do not outfeed
1D1 Size change incorrect
1D2 Outfeed/capper conveyor motor/gearbox fails
1D3 Drive sprocket fails
1D4 Conveyor belt fails
1
 5e No cap at cap chute
1E1 Cap feeder elevator motor/gearbox fails
1E2 Cap feeder elevator belt fails
1E3 Cap feeder elevator drive train fails
1E4 Bent caps
1E5 pneumatic failure at turnover box
1E6 Either air conveyor fans fail
1E7 Cap level in air conveyor fails
1E8 Caps jam in chute
6f Machine fails to apply cap
1F1Cap stops incorrectly adjusted
1F2 Boat incorrectly set
1F3 Cap chute height/angle set incorrect
1F4 Duckbill/hold down height/angle set incorrect
1F5 Jar not centralized
1F6 Sealing shoe height set incorrect
1F7 Any of the tension springs fail
1F8 Side belt rollers/pulleys seize
1F9 Worn side belts/sealing belts
1F10 Over filled jars
1F11 Side belt/sealing shoe drive train fails
1F12 Worn or incorrect set drag rubber

2) To metal detect above jars

2A Fails to detect metal in jars
2A1 Out of calibration
2A2 Infeed sensor fails
2A3 Shaft encoder or drive fails
2B Fails to eject detected jar
2B1 Pneumatic ejection system fails
3) To maintain product temperature
in filler bowl to 94c –100c
3A Fail to maintain temperature in
Water circuit

2
 3A1 No steam or regulator fails
3A2 Heat exchanger blocked
3A3 Pneumatic circuit fails
3A4 Temp probe or controller fails
3A5 Water jacket holed
3A6 Pressure relief valve fails open
3A7 Water pump or control system fails
3A8 Over temperature valve fails
4) To meet PUWER 98
4A Check list
5) Inject steam into head space
5A NO steam supply
5A1 Pneumatic system fails
5A2 Steam isolated
5A3 Steam slam valve fails
6) To fill and cap a product that is
safe to the customer
6A Fail to detect broken jars
6B Fills jars at below 92.5c
6C Incorrect or non fitting cap
7) To detect product level in
filler bowl
7A Fail to maintain correct level
7A1 Probe or control fails
8) To be able to adjust bowl height
8A Bowl does not move
8A1 Motor/gearbox fails
8A2 Drive train fails
8A3 Control circuit fails
8B Bowl does not stop
8B1 Low or high level switch fails
9) To be able to CIP and rinse
9A Fail to CIP
9A1 No water supply
9A2 Pump fails
9A3 Pneumatic system fails
3
 9A4 Water temp to low
9A5 No caustic dosing
9B Fail to rinse
9B1 No water supply
9B2 Pump fails
9B3 Pneumatic system fails
9B4 Water temp tow low
10) To be able to size change in
15 minutes
10A More than 15 minutes
10A1 Change parts not available
10A2 Gripper change over design

11) Safety 11A Safety checks 11A1 Cap hopper stop button fails
11A2 Cap hopper guard interlocks fail