PROVEN PERFORMANCE
IN EVERY PACKAGING CHANGEOVER

 

•    URETHANE STAR   

•    SPOTTING STAR   

•   ANTI-TORQUE STAR   

•   REMOVABLE POCKET STAR   

•   CHANGE PART INNOVATION

•   SMART STORAGE CART   

•   UNISON GRAVITY CHUTE   

•   UNISON AUTOMATION   

CASE STUDIES

 

URETHANE STAR

 

Customer Challenge

Customer wanted to reduce maintenance costs due to damage from broken glass during product handling. They wanted change parts that were more resistant to damage from broken glass while also reducing contain­er breakage. They also wanted to reduce noise levels during product handling.

 

About the Customer

The customer is a large multi-national beverage producer running glass bottles around the clock.

 

Solution

Septimatech developed a star design with a urethane contact surface to replace the plastic material that was used on existing parts. The existing plastic parts devel­oped sharp burrs and deformations when exposed to broken glass. The new softer urethane conforms better to the bottle, reduce noise and breakage. It also does not develop burrs or deformations when exposed to broken glass.

 

Customer Results

  • Customer experienced a significant reduction in noise and maintenance costs.

  • Change parts lasted longer with better resistance to wear.

  • Far less glass breakage reduced downtime and costs, while increasing safety for operators and maintenance personnel.

  • New parts were lighter and easier to changeover than OEM parts.

     

 

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SPOTTING STAR

 

Customer Challenge

The customer was having difficulty maintaining proper orientation of a container with an off-set neck and handle during filling. Customer needed a new change part that allowed proper filling and handling of the container at required production speeds. The product was a corrosive product which increased the need to eliminate miss-fills, splashing and spillage.

 

About the Customer

One of North America’s largest manufacturers of consumer, industrial, and personal care products and packaged goods.

 

Solution

Septimatech developed a dynamic spotting mechanism mounted to the infeed star that worked with rollers in the pockets to rotate the containers and lock them in place once proper orientation for filling was achieved. The design and materials were inert to the corrosive product and focused on eliminating miss-fills and splashing while maintaining production rates.

 

Customer Results

  • Containers were reliably and consistently oriented throughout the filling process.

  • Jams, splashing and miss-fills were virtually eliminated which resulted in less maintenance and downtime.

  • The customer increased production speeds and reduced costs from downtime.

     

 

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ANTI-TORQUE STAR

 

Customer Challenge

Customer needed to handle and cap a non-rigid container with a complex geometrical shape. The original machine part could not adequately support the non-rigid container while the high level of torque required to properly cap the product was applied.

 

Capping was inconsistent and some containers were being damaged resulting in slower production and higher costs.

 

About the Customer

The customer is a large multi-national manufacturer of consumer and industrial fabric and home care products. They package a wide variety of container shapes and sizes on the same line. Their line operates at high speeds around the clock. The wide variety of containers requires flexibility while maintaining precise control and consistent quality.

 

Solution

Septimatech developed a urethane pocket moulded to the exact geometry of their new container for full contact during capping. The new Anti-Torque Star provided needed stability and superior anti-torque capability.

 

Customer Results

  • Customer was able to effectively cap their containers with consistent quality at required production speeds.

  • Overall packaging efficiency and package quality improved.

  • Product loss was dramatically reduced.

  • New part provided outstanding return on investment in production rates, package quality, and reduced costs.

     

 

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REMOVABLE POCKET STAR

 

Customer Challenge

Customer wanted a more robust and cost-effective solution to their existing expensive crowner star assemblies for their high-speed, glass bottle packaging line.

 

Existing crowner star assemblies were causing declines in productivity and performance due to excessive wear, water absorption and glass damage.

 

About the Customer

Large multi-national brewery operating high speed bottling lines around the clock.

 

Solution

Septimatech developed a new ‘modular’ star design with a stainless steel skeleton and nylon pocket inserts that could be easily removed and changed in a couple minutes when damaged or worn.

 

The stainless steel skeleton provided a more robust design compared to the plastic incorporated by most crowner star assemblies. The nylon pocket inserts provided a durable but easily replaced component.

 

Customer Results

  • Effective life span of components increased.

  • Change part and glass damage were greatly reduced.

  • Replacement and maintenance costs for worn or damaged pockets were greatly reduced.

  • Maintenance time was significantly reduced.

  • Line performance and productivity increased.

  • New parts helped reduce the O2 content in the beer.

 

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CHANGE PART INNOVATION

 

Customer Challenge

Customer’s new larger container was too big for the filler head pitch.

The customer wanted a cost-effective and easy to changeover solution that would allow them to run a variety of containers on the line. 

 

About the Customer

The customer is one of the world’s leading producers of food and juice beverages with lines that run multiple products in different containers.

 

Solution

Septimatech designed and manufactured an innovative, alternating pocket star wheel that modified the existing 15 pocket start to pre­cisely skip feed and handle every other con­tainer.

 

Customer Results

  • The customer was able to reliably handle the new container without having to buy a new machine.
  • The customer’s line had more flexibility to handle a variety of different sized containers.

 

 

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SMART STORAGE CART

 

Customer Challenge

Customers needed to eliminate part loss and damage and reduce time for changeover. Customer also wanted to improve access and organization. 

 

About the Customer

Customers across multiple industry segments which require various line changeovers to run different containers or products. Customers share a common desire to make changeovers more efficient and improve organization and access to required change parts.

 

Solution

Septimatech provided a custom Smart Storage Cart for all machine change parts

 

Customer Results

  • Changeover time is reduced by having all change parts stored together and easily identified in accessible location near packaging line.
  • Part loss and damage were virtually eliminated.
  • Parts can be cleaned in cart making the process easier and quicker.
  • Parts were stored in a smaller footprint.
  • Identification of worn parts that need replacing is more efficient.

 

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UNISON GRAVITY CHUTE

 

Customer Challenge

Customer needed to convey multi-sized containers on a line at different elevations including inclines. Containers on inclines would fall forward and jam. Chute adjustments and jam fixes required ladders. Changeover was time consuming and not easily repeatable or accurate. 

 

About the Customer

The customer is a large multinational consum­er goods manufacturer of health, hygiene, and home products.

 

Solution

Septimatech installed its Unison adjustable gravity chute and guide rail system across the entire line, including, the inclines, straights, curves, and crossovers.

 

Customer Results

  • Changeovers reduced from hours to minutes.
  • All adjustments possible from ground floor.
  • All adjustments repeatable and accurate.
  • Repeatable top rail and container height adjustments eliminated bottle tipping
  • Health and safety risks eliminated.

 

 

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UNISON AUTOMATION 

 

Unison Automation provides manufacturers with the ultimate adjustable guide rail system. It combines the benefits of full, one-touch automation with the standard product handling and design benefits of the modular Unison adjustable guide rail system. The result is significantly faster, repeatable, and safer changeovers with the most precise container control available.

Changeover times are reduced from hours to minutes compared to non-adjustable guide rail systems and from minutes to seconds over the mechanically adjusted Unison system. Variations in set up created by different operators are eliminated, ensuring optimum performance with each change. Adjustments are repeatable and accurate to +/- 1mm or 2mm, delivering precise product handling every time. Guiderail changeover is confined to a single point, eliminating unnecessary operator activity and creating a safer packaging environment.

 

Changeover adjustments are fully automated through a programmable Human Machine Interface (HMI). Septimatech’s system allows users to automatically adjust all guide rails by simply selecting the desired container shape and size on a single, touchscreen HMI. Once the container is selected and changeover started, the system alerts operators to movement of the guide rails. As adjustments are made, the system provides feedback on the status and notification that changeover is accurate and complete.

Unison Automation includes precision engineered mechanical components and perfectly matched motors and controls to deliver precise adjustments and long, reliable service.

 

Customer Challenge

Customer with non-adjustable guide rail system wanted to fully automate changeover of its guide rails to reduce downtime, eliminate set up variables created by different operators, and improve safety. Customer also wanted to improve throughput and eliminate container scuffling, shingling, and tipping which slowed production and caused product damage. 

 

About the Customer

The customer is a large multi-national consumer goods manufacturer, which uses a wide variety of container shapes and sizes on the same line. The packaging line is complex with multiple crossovers, bends, and straight sections. It operates at high speeds around the clock. The wide variety of containers requires precise control to eliminate shingling, tipping and product damage. Production space is tight creating safety challenges and the need to eliminate unnecessary movement around the line.

Solution

Septimatech installed a fully automated Unison adjustable, beaded guide rail system across the entire line, including all mechanical and electronic components, motors, and control system. A single, touch screen HMI was installed and programmed for the customer. Training and follow up support was also provided.

 

Customer Results

  • Guide rail changeover time was reduced from 5 hours to 2 minutes. Mechanically assisted Unison guide rail system on a comparable line would take 18 minutes to changeover.
  • All adjustments initiated by selection of container size and shape on a single, touchscreen HMI.
  • Adjustments occurred immediately and simultaneously.
  • Adjustments are now repeatable, precise, and accurate to +/- 1mm or 2mm.
  • Operator variables were eliminated.
  • Precise adjustments and beaded guide rail reduced friction, ?scuffing, tipping, and container ?damage.
  • Overall production increased.
  • Overall costs were reduced.

 

 

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