Professional Documents
Culture Documents
Drum Filling Unit
Drum Filling Unit
2 OPERATING PHILOSOPHY
4 SPARES LIST
5 REFERENCE LIST
GENERAL ARRANGEMENT DRAWING
OPERATING PHILOSOPHY
ANNEXURE- I
OPERATING PHILOSOPHY, SEQUENCE OF OPERATION & SAFETY
INTERLOCKS OF FILLING LINE MACHINERY
1. Empty Barrel in-feed after removing bungs/ caps from metal/ HDPE Barrels
& after stenciling & any such operations to be carried out manually before
feeding the Barrels drums at the in-feed end.
2. Empty Barrels stops Automatically before Barrel Filling machine by stopper.
3. Empty Barrel is released by Foot switch operation by an operator of Barrel
filling machine & taken manually to the Barrel Filling station.
4. Empty Barrel is manually oriented on the roller platform of the Filling
machine below Filling lance with the help of bung locator.
5. Operator gives command for filling. Filling operation is carried out in three
stages as per the detailed sequence mentioned under Filling Machine
sequence of operation given below.
6. Filled Barrel is manually gently pushed to the adjacent Roller conveyor for
further operations.
7. Operator standing near the tools for bunging, sealing & any other such
operations carries out the same with respective tools & push the Barrel to
the adjacent Conveyor of Mechanical manipulator.
8. Filled Barrel/ Drums are Automatically diverted in two lanes for Palletising
operation & the further operation of Palletising is carried out as detailed
under mechanical manipulator’s sequence of operation.
Selector switches and Push buttons are provided to operate the system.
Manual Operation:
System can be operated by using the manual selection switches provided in the
operator panel.
Example:
When there is no Drum on the Weighing Platform, Filling Head will not go
down for filling. There will be “Place Drum” message for operator.
When the Empty Drums weight is out of tolerance, The system will not
start the filling operation and displays “Above Toll” or “Below Toll”
message. Until the Tolerance Weight comes within the Set target
(allowable limit) system will not start the filling operation.
Note:
o The above feature is provided,
To avoid using half filled Drums or Drum with some material
To avoid filling some other capacity Drums not related to the
actual one.
Ball valves will be operated only when the filling valve is completely down
and after checking / confirming the empty drum weights.
When the Filling Valve is going down towards the Bung of the Drum,
suppose if it hits the Drum, System will stop the operation and Lifts the
Valve UP with the message “Bung Wrong”.
When Power fails during filling, On power resumes, the operation
can be started by pressing Fill Start command. System will continue
the filling operation from the weight already filled.
Foot Valve will not open unless the Drum Weight comes within tolerance
Limit.
Note: During filling, if there is no material flow, filling nozzle will be waiting
till the material weight reaches to the target.
MECHANICAL MANIPULATOR SYSTEM‟S DESCRIPTION AND OPERATION:
It consists of powered roller conveyor for conveying filled Barrels initially in single
row. Total length of Powered roller conveyor shall be 1800mm and then the drums
are diverted forming double row.
One diverter is provided for dividing two barrels one after other. Divider will
have one long arm and two short arms, as the barrel pushes one of the short
arm while traveling through conveyor, the long arm changes its position and so on
one after the other barrels will pass through conveyor and divided in to two rows.
The PLC provided, controls the movement of the barrel into the transfer area and
one after the other barrels are released through pneumatic stopper by PLC
control. Divider side face is provided with frictionless rollers to prevent
scratching the barrels.
At the discharge end two pairs of stoppers are provided from top to prevent further
movement of the barrels. Stoppers are mounted on a single channel and connected
by a pair of lever fitted below the rollers.
Levers are fitted with a fulcrum pin at one end. Thick plate is provided at a
discharge end for supporting and adjusting the barrels.
Operation :
Filled barrels are first conveyed by Powered Roller conveyor to the manipulator
section & then automatically diverts the Barrels on either side of manipulator
gravity roller conveyors by use of automatic diverter operated by pneumatic
stopper which activates by PLC.
The Fork Lift operator brings a pallet (assuming 1250x1250) on its fork and pallet
is inserted below the palletizer upto the stopper provided. Then the Forklift
operator raises the lever by the pallet on fork. As the lever is raised the stoppers
for the barrel get lifted and barrels (2 x 2) slides on to the pallet. Then the fork is
lowered and reversed. Moment the fork is lowered and stoppers come down due to
its weight and stops the rear barrels. The fork lift operator also adjust two barrels
by pressing against the front thick plate. The total time taken to do the palletizing
of 2 x 2 barrels on a pallet depends on the skill of the forklift operator; generally
experienced forklift operator completes cycle of palletizing in a minute time.
QUALITY ASSURANCE PLAN
QAP (QUALITY ASSURANCE PLAN)/ ITP (INSPECTION TEST PLAN):
GENERAL INSPECTION:
3 Readability 50 gm
GENERAL INSPECTION:
SPECIFICATIONS OF CONVEYORS:
Mechanical Manipulator for palletizing of 210 Kg. Filled barrels in two rows
having configuration of 2 x 2 x 1 of barrels.
Mechanical manipulator receives Filled barrels in the single row and then coverts
in to double rows. One diverter is provided for dividing two barrels one after other.
Divider will have one long arm and two short arms, as the barrel pushes one of
the short arm while traveling through conveyor, the long arm changes its position
and so on one after the other barrels will pass through conveyor and divided in to
two rows. The PLC provided, controls the movement of the barrel into the
transfer area and one after the other barrels are released through pneumatic
stopper by PLC control. Divider side face is provided with frictionless rollers to
prevent scratching the barrels.
At the discharge end two pairs of stoppers are provided from top to prevent further
movement of the barrels. Stoppers are mounted on a single channel and
connected by a pair of lever fitted below the rollers. Levers are fitted with a
fulcrum pin at one end. Thick plate is provided at a discharge end for supporting
and adjusting the barrels.
Operation:
Filled barrels are conveyed through the adjutant conveyor to the Powered Roller
conveyor and Filled barrels are further conveyed to the manipulator section.
The Fork Lift operator brings a wooden pallet (1250x1250) on its fork and pallet is
inserted below the palletizer upto the stopper provided.
Then the Forklift operator raises the lever by the pallet on fork. As the lever is
raised the stoppers for the barrel get lifted and barrels (2 x 2) slides on to the
pallet. Then the fork is lowered and reversed. Moment the fork is lowered and
stoppers come down due to its weight and stops the rear barrels. The operator also
adjust two barrels by pressing against the front thick plate. The total time taken to
do the palletizing of 2 x 2 barrels on a wooden pallet depends on the skill of the
forklift operator; generally experienced forklift operator completes cycle of
palletizing in less than a minute time.
Specifications :
PLC : Delta.
Shaft : 16 mm.
SPARES LIST FOR BARREL FILLING LINE FOR ONE YEAR OPERATION
Screw Air Compressors Nitrogen Generators Machine Tools Fume and Dust Extractions High Pressure Air Compressors
Germany UK UK Sweden Germany
REFERENCE LIST
REFERENCE LIST:
Two Complete Lube oil barrel Filling Lines including Automatic Palletizing,
having capacity of 160 barrels / hour of 210 Ltr barrels from OCME S.r.l .
Complete small can Volumetric filling line, having capacity of 120 cans/min
of 1 Ltr size containers together with complete automation.
Complete small can filling Line for filling 500 ml to 6 ltrs. Containers using
16 heads twin track electronic inline filling machine, having capacity of 80
cans/min of 1 Ltr size containers together with complete automation. This
was executed with manufacturer rendering FILLPACK’S techno-commercial
support.
Two numbers semi automatic Barrel filling lines with mechanical manipulator for
Palletising recently commissioned.
Complete Barrel filling line with auto Palletising capacity 100 barrels / hour
supplied by OCME, ITALY and serviced by FILLPACK.
INDIAN OIL CORPORATION LTD, TADEPALLY ( ANDRA PRADESH)
Two Nos. Complete Automatic Barrel Filling Lines with Palletizing System each
having filling capacity of 120 Barrels per hour . This order is being supplied and
executed with the machines manufactured by OCME and installation &
commissioning will be carried out by FILLPACK. This order is under execution and
will be completed before 31.03.2014 .
Two nos complete small can weigh based filling lines, having capacity of 120
cans/min of 1 Ltr size and 50 cans/min of 5 Ltr size from OCME S.r.l
Two nos complete Sticker labelling machines, having capacity of 120 cans/min
of 1 Ltr size and 50 cans/min of 5 Ltr size.
Complete Fully Automatic Small Can Filling Line starting from unscrambler till
Auto-cartoning and Palletizing, Filling capacity 120 cans per minute to be
installed & commissioned at Silvassa . All the machines are supplied by OCME
S.r.l. Italy.
One Complete Lube Oil Barrel Filling Line including automatic depalletizing &
palletizing, having capacity of 120 barrels/hr of 210 Ltr from OCME S.r.l
One Complete Lube Oil Pail Filling Line including automatic depalletizing &
palletizing, having capacity of 300 Pails/hr of 20 Ltr from OCME S.r.l
Complete Lub oil Filling Line for Barrels including Palletiser & Complete Pail
Filling Line.
Complete small can weigh based filling line ( Filling & Capping machine from
OCME Italy), having capacity of 120 cans/min of ¼,1/2, 1 Ltr size containers
together with Auto Cartoning System.
Complete Semi Automatic Filling lines with conveyor system for filling
lubricating oil in 210 ltr. Barrels capacity each 25 – 30 barrels .
Complete 4 Nos. Semi Automatic Filling lines with conveyor system for filling
Break Fluid and coolants / lubricating oil in 210 ltr. Barrels capacity each 25 –
30 barrels .
Complete Pail filling lines Capacity 400- 600 Pails per hour recently
commissioned.
Complete Barrel filling line with auto palletising capacity 100 barrels / hour
supplied by OCME, ITALY and serviced by FILLPACK.
Two no.s Robotic Palletising system for filled cartons, pales/ drums supplied by
OCME, ITALY and serviced by FILLPACK.
Four numbers fully automatic filling lines using Linear Spur gear electronic dosing
filling machines capacity 3000 CPH.
Two Nos. Semi Automatic Barrel filling Lines and One No. Pail Filling Line
One No. Fully Automatic Filling Line using Rotary Piston Filler capacity 100 bpm .
The above Filling lines are commissioned before 15th Dec 2013.
SPECIAL NOTE: All the above references are for the major projects executed only
in the field of lube oil industry where FILLPACK either supplied directly or had
direct involvement in execution with their principles/ business associates.
FILLPACK with their association with OCME and LAN FRANCHI have executed
many machinery for other industries.