We've meticulously re-engineered key components to boost your packaging line's efficiency, reduce maintenance, and extend equipment life.

1. Upgraded Cylinder Durability & Precision:

• Materials: Constructed with all-welded Stainless Steel cylinders, Stainless Steel guide & piston rods, durable Delrin bushings & pistons, and reliable rubber U-cups.

• Benefits:

  • Superior corrosion resistance for longevity.

  • Minimized wear, ensuring constant and precise cylinder lift.

  • Essential for handling delicate PET containers effectively.

2. Greaseless, Low-Maintenance Cam Followers:

• Innovation: Replaced traditional high-maintenance steel rollers with advanced greaseless cam followers.

• Benefits:

  • Eliminates: Routine lubrication and associated maintenance costs.

  • Reduces: Wear on the pull-down cam.

  • Saves: Approximately two-thirds the cost compared to old steel rollers.

3. Adjustable Guide Rods for Quick Tuning:

• Feature: New Stainless Steel guide rods allow for individual cylinder height adjustment.

• Benefits:

  • Rapid Adjustments: Correct sealing or filling issues at specific valve stations in seconds, not hours.

  • Increased Uptime: More filling time and significantly less product loss.

  • Flexibility: Fine-tune performance easily.

4. Optimized Cylinder Lift for Efficiency & Longevity:

• Refinement: Precisely limited cylinder lift distance.

• Benefits:

  • Improved Handling: Smoother bottle handling and transfers into the filler.

  • Precision Lifting: Ensures exact bottle positioning.

  • Reduced Wear: Less stress on cylinders and the pull-down cam by limiting pressure during entry/exit.

  • Extended Life: Increases the lifespan of critical components while boosting filling efficiency.

5. Reliable & Efficient Variable Frequency Drive (VFD) System:

• Modernization: Replaced hydraulic drives with a state-of-the-art, electrically driven VFD system mounted underneath the filler.

• Benefits:

  • Increased Reliability & Efficiency: Proven performance gains.

  • Decreased Maintenance: Eliminates hydraulic system upkeep.

  • Enhanced Safety: Removes potential contamination risks associated with hydraulic oils.

6. Advanced Infeed Safety Gate:

• Functionality: Monitors bottle flow and provides manual control.

• Benefits:

  • Jam Detection: Automatically activates a safety switch if bottles jam in the worm screw.

  • Manual Bottle Stop: Allows operators to halt incoming bottles without stopping the filler's rotation, preventing unnecessary shutdowns.

  • Protection & Efficiency: Enhances filler lifespan and improves overall operational flow.

7. Precise Electro-Pneumatic Valve Openers with Smart Control:

• Technology: Replaced pneumatic openers with a highly accurate electro-pneumatic device managed by a Programmable Logic Computer (PLC).

• Benefits:

  • Accuracy & Precision: Ensures consistent valve operation.

  • Reduced Complexity: Features fewer moving parts.

  • Gentle Handling: Does not contact the bottle – ideal for PET containers and pre-labeled packages.

  • Smart Detection: Utilizes state-of-the-art sensors to identify missing or downed bottles in the infeed.

  • Instant Response: The PLC instantly signals the opener to keep the valve closed if a bottle is missing.

  • Zero Loss: Prevents product and CO2 loss, maintaining stable bowl contents for quick operational resumption.

  • Low Maintenance: Virtually maintenance-free once installed.

  • Easy Adjustment: Bottle detection heights are easily adjusted via banner sensors.

  • Cost Savings: Can often utilize the existing timing collar (if star wheel pockets match), reducing changeover time and costs associated with lost product/CO2.

8. Maintenance-Friendly Valve Closer Tracks:

• Design: Re-engineered using durable Stainless Steel with sloped tracks, optimized for the new style valve lever.

• Benefits:

  • Built for Maintenance: Designed with the maintenance crew in mind.

  • Easy Spring Replacement: Tension springs are mounted externally, allowing replacement in minutes when wear occurs.

  • Durability: Stainless steel construction ensures longevity.

9. Comprehensive Finishing Touches:

• Final Overhaul: Includes rebuilding the liquid level control and implementing all-new gauges, diaphragm valves, hoses, and stainless steel connectors.

• Benefits:

  • Optimized Distribution: Increases the overall efficiency of product flow.

  • Corrosion Resistance: Minimizes corrosion from chemical sanitation and product spillage.