Presentation

program

HB
 
There are different machines in bottling
process. These are;
 De palletizer
 un packer
 Bottle washer
 Crate washer
 EBI
 Check Mat
 Filler
 FBI
 Pasteurizer
 Labeler
 Packer
 Palletizer
 Depalletizer

Is a robotic system which is used to separate pallet and empty bottle

with crate.it has some components such as base, belt conveyor,
controller sensor, actuator and effecters (gripper).
Base: - the base of de palletizer is fixed to ground for the purpose of
every activities stand with balanced.
Belt: - is a mechanical part of de palletizer which is used degree of
freedom for the purpose of moment with in the direction of up and
down and also sliding mechanism motion.
Controller: - it is a device with hard and soft ware support for giving
commands to the drive.
Sensor: - it is used to give feedback information for subsequent action
of arm (mechanical gripper) as well us to interact with the environment
which the de palletizer is working
Actuator: - it is a device which is used to causing the manipulated arm
(effector) to move.
End effecter (gripper):- is a part of de palletizer which is used to holding
the required part of the bottle.
End effecter (gripper):- is a part of de palletizer which is used to
holding the required part of the bottle.
 Un Packer
It is a machine which is used to separate empty bottle from crate by using
pneumatic system and effectors (grippers).

It has two motion mechanisms.

1.oscillating mechanism:- orented by gear box to hinged pillar push
rod,crank,cross transport drive and function tube to perform their
functions
2.up and down motion by the belt driver associated host motor.

Crate washer
After separating the crate and empty bottle the crate inters to the crate
washer for the purpose of cleaning and dry by using spray mechanism
with in warm water and caustic solution.
 
 Bottle washer
The main mechanical components of bottle
washer are: -

• Pumps
• motor (main drive)
• Gear boxs
• Chain conveyor
• In feed
• Discharge
• spray nozzle
• Universal joint
Types of pumps installed in the bottle washer with their function are: -

Axial pump: - is used to control the viscosity of caustic.

Jetting pump: - is used for the cleaning interior and exterior parts of the
container (bottles).
Driving system:-the main driving system of the bottle carrier is electric motor. The
force and / torque transmitted to different lines through the following
components:-
Motor and gear box
Shafts, sprockets, chain conveyor with pockets, and locks
Universal joints
 
Gears:-it used for power transmission and for easily moment mechanism. The
main preferable gears in the bottle washer are warm and bevel gears.
Bevel gear:-is used for power transmission in the place of in feed and
discharge position only.
Worm gear:-is founds at every gear boxes for the purpose of the rotational
motion change in to linear motion from each gear box placed position.
Universal joints:-is used transmit force and/ torque from the main drive (motor)
to different gear boxes.
Sprockets:-are used to transport or drive the chain pockets by the rotating
shafts via their teethes.
Shaft:-it is connected to gear box and bearing house is used transmit power
from gear box to the sprockets.
Bearing:-use to support shaft from sliding and to be smoothly rotates.
chain conveyor with Pockets:-it is used for the purpose of transmiton of bottles

Infeed :-The in feed activity is performed by the mechanism of gear, shaft,

piston, pusher rod, bearings system. The main purpose of in feed is to
reduce the over loads and the power transmission is controlled by bevel gear
system.
Pneumatic cylinder:-is used to absolve the torque at the safety gear by
determining the tripping sensitivity of the over loading protection unit.
Universal joints:-is used transmit force and/ torque from the main drive (motor)
to different gear boxes.
Sprockets:-are used to transport or drive the chain pockets by the rotating
shafts via their teethes.
Shaft:-it is connected to gear box and bearing house is used transmit power
from gear box to the sprockets.
Bearing:-use to support shaft from sliding and to be smoothly rotates.
chain conveyor with Pockets:-it is used for the purpose of transmiton of bottles
Discharge:-used for good treatment of the empty bottles.
It works by synchronous drive
Smooth and silent setting down of the bottles
A good transfer on to the discharge conveyor
In bottle washer used to only one motor for all activities by synchronies
operation system with in the universal joint arrangement force and torque
transmission as required process.
 
Steam:-it is themain source of heat for caustic and it is comes from utility
(boiler).
The caustic in the tank is heated up using steam using plate heat exchenger by
conduction process transfers heat to the tank and the caustic will become
heated and the steam condensed back to boiler for reuse
Crate washer
After the bottles remove, the crates will travel to the crate washer which washes
the crates through the conveyor with water by consecutive levels

Bottle filling
Steps on beer filling process are:-
pre evacuation1
Rinsing 1
Pre evacuation 2
Carbon di oxide filling
Filling of beer
Releasing
pre evacuation 1:-after lifting, the bottle pressed, air tight, against the filter head
by centering tulip and the vacuum valveis opened by a fixed stop, with in very
short time 90% of the evacuation of thebottle is achieved.
A vacuum protection device which is raised by centering tulip prevents collapse
of the vacuum when no bottle is raised.
Rinsing (carbon di oxide flashing):-as a result of actuation of the rolle lever
the gasvalve is briefly open and carbon di oxide pass in to the bottle from
the filter bowl and purges the bottle. This process is lasts only a very short
time and is ended by the return of the roller lifter to its original position.
The pressure in the bottle increases about atmospheric pressure.
Second evacuation (pre evacuation 2) :-the process described for phase 1
is repeated and again in an approximately 90% vacuum is produced. This
vacuum sucks out the still present air with the carbon di oxide from the
bottles. The air friction in the bottle sinks to 1%.
Counter presurization(carbon di oxide filling):-the processin the phase 2 is
repeated but for a long time. The carbon di oxide flowing in produces a
high carbon di oxide concentration in bottle after the two fold evacuation.
Symultaniously the pressure in the bottle is raised to the same pressure as
in annular bowl.
 Filling beer:-the beer now can flow down wards and is deflected by the
deflection cone against the bottle wall and flows down the wall as thin film. The
carbon di oxide displaced flows back in to the bowl through the air pipe.
Releasing:-as soon as the beer reaches the end of the vent tube it rises in this to
be and the gas above cannot escape. The beer valveis closed and the gas
valveremains open, carbon di oxide at a same over pressure enters the neck of
the bottle and the beer above the vent pipe is forced back in to the filler bowl.
An exact filling hight can so be obtained.
HPI (high pressure injection) system:-is used to inject hot water in to the bottle
to produce foaming and displace (protect) the residual air entry to the container
before the bottle passes to the crowner.
Crowner:-is used to close the bottle faster by the crown corks in order to prevent
the beer from contaminants and entering gases.
Components (functional) parts of filling machine are:-
 
- Indeed and discharge
- Starwheels
- Carousel
- Vacuum pump
- HIP
- Guards...
 Safety equipments installed in the filling machine are :-
- Different sensors like photo cell sensor
- Safety door, and
- Guards
Safety equipments are used to protect persons from:-
- Moving machine parts
- Noise
- Splashing liquids, and
- Broken containers
Pasteurization
Pasteurization is simply means to destroy or to reduce the number of harm full
microorganisms in a product in order to increase its biological stability
- Temperature zones:-
- Heating zone
- Pasteurization zone
- cooling zone
- Pasteurizer has 6 process zones :-
• First pre heat ( for 5 minute at 35-50 degree centigred)
• Second pre heat ( for 13 minute at 50 - 62 ")
• Pasteurization zone ( for 20 minute at 63 ")
• pre cool ( for 5 minute at 60-49 ")
• Cooling ( at 49-30 ")
• Service water, ( for two minute at 30-20 ")
 Bottle decoration (labeling)
In the unending struggle for market share, the appearance of the bottle is very
important. The number and size of labels, their color and design, their arrangement
and the overall effect should be show for the customer that is producer’s beer but
not only the best it also the most attractive
Labeling is also describe –expire date of the beer
-chemical content
-gradient and
-place of product
Driving system
 
Main drive:-is an electric motor with its own gear box, and is used to chenge
electrical energy to mechanical energy, which is a source of energy for spur
gears
Driving gears :-at the bottom of labelling station there are groups of spur
gears that enable to drive all the top part of lebler machine ( like carrousel,
gripper cylinder, glue pallets, glue roller parts ) via their respective shafts.
Hight adjustment motor:- is found at the bottom of the carrousel which is
used to adjust the hight of the carrousel to increase or decrease as it is
needed.
 Basic groups of labeling machine
Conveyor infeed :- containers are conveyed to the infeed warm through it.
Infeed warm :- increases the spacing between the containers unit it
corresponds to the pitch of infeed star wheel
Infeed star wheel :- is used to transfer the container to the container table.
Discharge star wheel :- takes the labeled container from the container table
and transfer them to the discharge conveyor.
Carrousel :- is driven by the main drive. Depending on the design the container
table is may be height adjustable. In Raya brewery labeling machine is height
adjustable.
The carrousel comprises
- Container plate
- Labeling station
- star wheels
Container plate :- the containers are firmly clamped between the container table
plate and centering bells of the container table and used to rotate containers
around the carrousel.
Labeling station :- used apply appropriate labels to the container using different
labelling methods.
Centering bells :- containers are firmly clamped between centering bell and
container table plates.
Major functional parts of glue units are :-
- Glue pump :- used to pump glue from glue container to glue scraper.
- glue scraper :- is used to carry glue and is found a small clearance ( gup )
from the glue roller. The gup between them is adjustable.
- Glue roller :- the gup between glue roller and glue scraper determines the
filam thickness and it can be precisely adjusted with adjusting screw.
- Glue pallets:- take or coated with glue filam from the glue roller and
withdrew labels from label magazine. After withdrewal they are further
convey labels to the gripper cylinder.
- Gripper cylinder :- removes labels from glue pallets and transfer the
containers. gripper fingers can pick up the labels evenly from the pallet and
transfer it to the container.
Major functional parts of labelling station :-
- Nack labels
- Body labels, and
- Back labels
Major functional parts of gripper cylinder :-
- Gripper fingers
- Sponge
- Pneumatic air, and
- cam
Major mechanical parts of the carrousel :-
- Centering bell
- Container plate
- Brushe - Labelling stations
The two types of pumps installed are :-
1. Oil pump :- used to pump oil for lubrication
2. Glue pump :- used to pump glue for labelling
Mechanical setting of labeller machine are :-
- Pusher distance
- Pusher hight
- Rejection monitoring unit
- Acknowl trigger
- Under fill
Type of ubrications in the labeller machine
 
Lubrication is the application of some amount of oily or greasy substances in order to
diminish friction. The oil and grease are most common lubricates in the labeller machine
parts.

Grease is used parts are :-

- The top part of glue roller and glue pallet
- The top part of carrousel
- Centering bell, and
- Manually used for Spur gears found at the main drive
 
Oil ep3 used to lubricate parts :-
- Gears at the glue roller and glue pump
- Gears at the bottom side of container plate
 
Packer
It is the same as unpacker but the difference is packer is bottle loading or
inserting in the crate & unpacker is removing the bottle in the crate. So the
same structure & working principle, different
Palletizer
Is similar to de palletizer in their construction but different in their function and degree
of freedom. In palletizer number of sensors are much amount than de palletizer even
crate pusher machine is present in palletizer but in de palletizer. The moment of
palletizer is up and down sliding and also rotational motion is presence but not in de
palletizer. Other components are the same to the one