This year, Pace is introducing two new
innovations in unscrambling technology: Omni-line High Speed Unscramblers
and Pharma-line M300 with a “No Change Parts” option.
Omni-line M800 & M1000 High Speed
Using a newly introduced patented Pace technology, the M800 & M1000 High
Speed unscramblers continue to push the envelope of attainable bottle
speeds. This proven technology runs light-weight PET 500ml bottles at 675+
"No Change Parts"
For the Pharmaceutical industry, the new “No
Change Parts” option further decreases the time required for changeover,
resulting in increased efficiency and production time. This new system
runs round bottles ranging from 30cc to 500cc, while bottles outside this
range can be run by our standard systems.
Barr Laboratories' new integrated packaging line
runs 10 bottle sizes and 60 different products at 100 bottles per
by Jack Mans, Plant Operations Editor
A new single-source integrated packaging line is
providing big benefits for Barr Laboratories' solid-dosage tablet and
capsule plant in Forest, VA. Installed a year ago, the
100-bottle-per-mintue line runs all 10 bottle sizes (30 to 1,500cc
capacity) and all 60 products packaged at the plant. "With its
toolless changeover capabilities, this equipment is ideal for all of the
different packages we run," says associate director of packaging Chris
Runs 100 bottle per minute
Plastic bottles are delivered to the line in paperboard
boxes, and an operator dumps them into a hopper, where they enter a
Pharma-line 300 unscrambler manufactured by Pace Packaging Corp.
The bottles discharge from the hopper onto a conveyor transporting them
past a series of wheels and belts that turns them to the proper
position. The unit at Barr Labs is equipped with an optional
ionized air rinse with a concurrent vacuum. Bottles are placed in
an inverted position so that the air can be blown upward into them, and
any solids will fall out. The bottles are turned into an upright
position before they leave the machine.
The bottles then travel to a Model CF-1220-D dual-head
electronic tablet filler manufactured by Cremer Packaging Technology.
"NJM/CLI did an excellent job for us on this project.
Installation and startup went very smoothly, and the line has run very
well right from the beginning," says Baker.
Bottles discharge from an unscrambler hopper onto a conveyor, below
left, that transports them past a series of wheels and belts that turns
them to the proper position.
Reprinted from PACKAGING DIGEST September 2002
Copyright 2002 by Reed Business Information, a division of Reed Elsevier
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Vitamin maker counts on electronic filler
sales growth at Jamieson Laboratories made it obvious that a new vitamin
packaging line was needed. Electronic tablet counting brings big
Pat Reynolds, Features Editor
Unscrambling is first
on Jamieson's new line are either high-density polyethylene (primarily for
contract customers) or polyethylene terephthalate. They enter the line by
way of an Omni-line Model 350 unscrambler supplied by Pace (Fairfield, NJ).
Bottles are placed directly
onto the customers conveyor by way of Pace's Omni-line Model 350
reach the tabletop conveyor that carries them through electronic
filling, a diverter sends them down one side or the other of a lane
divider. This permits the Cremer to fill two-up.
bottle filled on the line has an internal volume of 60 cc, the largest
375. Products include gelcaps, tablets and two-piece capsules. All
product is fed into the line through a bulk bin that holds the contents
of seven 20-L pails. Once this hopper is full, an operator hits a switch
to elevate the hopper up to two overhead hoppers that feed directly into
the Cremer machine. Cook says the floor-level bin is a welcome
improvement over the method used on the old line. "It's nice not having
to run up and down manually filling an overhead hopper," he says.
Each side of
the twin-fill Cremer machine has three 12-channel vibrating pans. As
tablets drop from the hopper into the first pan, they're essentially in
a bulk flow. By the time they're vibrated to the second pan, they begin
to separate from each other. By the third pan, the tablets are neatly
aligned end to end in their channels. All that remains is for the tablet
to be counted as it drops out of its channel and passes the counting
correct number of tablets has been counted into the delivery chute,
memory flaps are shut above the chute so that the product for the next
bottle can begin being counted immediately," says Cook.
filler, bottles are conveyed to a cottoner and then a capper, both from
NJM/CLI. Each cap has a foil liner that's induction-sealed, shortly
after the capper, by an Enercon (Menomonee Falls, WI) system. "It
produces a nice, clean seal, and it's easy to run," says Cook.
Excerpted from "Vitamin maker counts an electronic filler" Packaging
World¨ January 2000 www.packworld.com
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Rug Doctor prescribes equipment changes for overhauled bottles, labels
Prompted by a major overhaul of bottles and labels,
Rug Doctor revamps an existing bottling line to handle the new packaging
and creates a speedier setup in the process ... as visited by Rick
Lingle, Senior Editor.
The equipment here is literally what the Doctor ordered-
Rug Doctor, that is. Equipment upgrades made over the years at its
Fenton, MO, plant accelerated in mid-'98 when the Plano, TX-based
company converted to drastically redesigned bottles. Previously
round and white in a look best described as industrial, those
existing bottles were replaced with new asymmetric bottles with a
flair and a look that is more solidly retail.
Setting the pace for the faster speeds are the Omni-line Model
M-500 unscrambler and orienter from Pace. Bolted together as an
integrated unit, the machinery's compactness is a plus for the Rug
Doctor's space restrictions, notes Brandel, along with service and
the overall "heavy duty" design. Dumped from bulk corrugated bins,
bottles travel from a 75-cubic- foot hopper onto a rotary table from
which they discharge in an end-to-end position on the orienter's
conveyor. The 16- and 32-oz bottles, molded by CKS Packaging, are
provided by Berlin Packaging. Run on the adjacent line, 64- and
128-oz bottles are molded by Liquid Container.
Bottles are then uprighted and oriented, if needed, into a
neck-leading position. Brandel calls the integrated Pace machines an
"outstanding" system. RD personnel had focused in on the Pace
machines at the Pack Expo West show, sponsored by the Packaging
Machinery Manufacturers Institute, in Las Vegas in '97.
convey to the infeed starwheel of the Laub/Hunt air-operated, gravity
flow filler installed in '95. It had been selected for its speed and
"soft handling" of the company's foamy products, RD says. It was also
customized with a "foam extractor unit" built in-house using one of the
RD's own industrial vacuum cleaners. Mounted atop the filler in late
'98, the "FEU" basically sucks foam from the top neck opening of the
bottles on the discharge starwheel through the attached vacuum hose.
remains the same: a Model NRC-30 unit from The New Resina Co., that
applies the caps to the bottles and uses three sets of rubber wheels to
tighten them. As Resina cappers have long been a favorite on Rug Doctor
production lines, this particular model was added in '95 for its
"simplicity, flexibility and overall durability and endurance." RD
personnel note that it accepted the new bottle styles without upgrading.
obtained through Berlin Packaging, are manufactured by two suppliers:
Seaquist produces the 28/400 polypropylene flip-top closures used on
pint sized bottles while Top-Seal produces the 28/400 flat-top PP
closures used on all other sizes. The flip-top closures have a foil
laminate innerseal while the flat-top closures have a foil laminate on a
polymer foam backing. For the two larger bottles, 38/400 closures are
used. Several days a month, a purple trigger sprayer from AFA, also
obtained through Berlin Packaging, is manually applied and run through
the capper, although RD expects to automate trigger application sometime
in the next several months.
bottles proceed through a new addition to the line made in '98: A
Filtec¨ Model FT-50 level detector from Industrial Dynamics. Brandel
calls it a "very reliable, excellent piece of equipment that ensures
that there are no underweights." RD claims overfills are under two grams
on the pint bottle. Complete with reject station, the Filtec machine
replaces a checkweigher that Brandel says "had maintenance issues and
required constant operator adjustment. Once it is set, the Filtec unit
requires no adjustment."
continue on through a "medium sized" induction sealer, an Integral II
2-kw system from Enercon Industries added in '97. Brandel says that it
was chosen for its tunnel design head to allow them to seal the
between twin Willett Labeljet¨ Model 230S labelers, one on each side of
the As conveyor, for front and back label application that is made
simultaneously. RD added squeegee wipedown to the labelers, which is now
an option on Labeljet units, PD is told. Containers pick up labels on
two sides as they pass twin peel plates from both sides of the conveyor.
sport front and back pressure-sensitive labels rather than the previous
glued, wraparound paper labels, which RD managers say had a tendency to
split on the larger bottle sizes. Leach acknowledges that the p-s labels
are more expensive, but "they have enough off-setting benefits along
with a better image that makes them a worthwhile investment." Advantages
to the p-s labels cited by RD personnel include: cleanliness,
appearance, chemical resistance and safety, the latter being the
elimination of glue pots heated to near 300 deg F.
uses three types of labels, all from nearby Foremost Printing. A white
polyolefin substrate flexo-printed in four process colors is used as the
facestock for all four bottle sizes as well as for the back labels on
the two largest bottles, 64 and 128 oz.
Reprinted from PACKAGING DIGEST¨ June 1999 © 1999 by CAHNERS BUSINESS
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Seagram scrubs downtime
Continuous conveyor cleaner reduces downtime and spill problems on its
filling line for liqueurs. The mop-up team has been reassigned.
At Joseph E.
Seagram & Sons. distinctive flavor and elegant packaging play major
roles in the success of two imported liqueurs, Vandermint and Cherry
taste better than they run, however. On Seagram's filling line at
Dundalk, Md., the sugar and syrup content of the products can play havoc
,with conveyors when unavoidable spills occur. This was especially true
on an out-of-the-way spiral conveyor. Seagram engineers first tried a
water bath but found that this created more problems than it solved.
Pucks (top) carry
liqueur bottles through Seagram filling line. Spiral accumulating
conveyor (bottom) has scrubber (left) on return side.
Eventually the big distiller discovered Pace Packaging's conveyor
scrubber at a Pack Expo exhibit and has found it to solve most of
the conveyor chain breakage problems as well as those that were
created by the water bath.
difficulty with spillage actually traces back to the packages
themselves. The bottle shape makes them somewhat top-heavy. That
presented conveying difficulties, especially at the filler.
top-heavy bottles had a tendency to fall over when filling," comments
Casimir Razulis, bottling development engineer. "That's why we developed
special plastic carrier pucks." The pucks help to stabilize the bottles
on the filling line, from filling through capping and labeling. After
labeling, the bottles are picked up by their necks as they move toward
the packing station; the pucks simply fall off onto a puck accumulation
accumulation conveyor was redesigned into a spiral-style conveyor
filling capacity was greater than puck accumulation. Pucks would
eventually back up onto the filling line and jam it. To fit this
higher-capacity conveyor into the plant layout, it was necessary to run
the conveyor through a wall and into an area normally used for storage.
"Even with our puck bottle carriers, some spillage is inevitable,"
Razulis comments, "First the liquid drips onto the pucks and then onto
the conveyor, often while the puck is negotiating the accumulating belt.
When these liquid sugars dry, the plastic conveyor links are virtually
welded together, Eventually, it will cause the chain to break. Then we
especially true for the spiral accumulation conveyor because its design
requires the links to flex around curves. "The long length of this
conveyor makes cleaning even more critical for us. We have more drive,
more pull-just more conveyor than the straight filling conveyor. By the
time the pucks drop onto the accumulation belt, the sugars and syrups
are already starting to dry on the pucks and are dripping onto the
conveyor," Razulis adds.
spills build up between the links, the tendency of the plastic conveyor
was to jump out of the track. That was precursor to a break, states
Daniel Adamchik, packaging engineer.
these periods of downtime, which would force shutdown of the filling
line, the plant first tried an open water bath for the accumulation
conveyor. The return side of the plastic belt was run through a water
trough, then blown dry by air jets. This technique did help to reduce
conveyor breakage and line downtime. But its effect on plant conditions
became a major drawback.
bath was a mess," Razulis states flatly. "There was a tremendous amount
of water on the floor because the conveyor had to be saturated to keep
it moving. We had to assign two people to mop the floor to keep up with
spills from the trough,"
regular mopping, the wet floor surface became a plant safety hazard. And
the engineers discovered that water seepage was beginning to cause
deterioration of the wall that separates the filling line from the
accumulation conveyor. The mess also caused damage to some of the
supplies in corrugated cases stored nearby.
Minimal water now
"When we saw the Pace cleaner at a Pack Expo show, we decided that
it was a more modern approach to cleaning the conveyor," Razulis
recalls. In addition, the cleaner was so inexpensive that the engineers
didn't need to work up a full economic justification for its purchase.
Its payback has been both fast and apparent to plant operations.
"When you realize that we used to have two people
mopping the floor. we've saved substantially on labor alone. And when
that conveyor would break, we lost production time. So it's obvious that
the cleaner did not take long to pay for itself," the bottling engineer
As the return side of the accumulation conveyor moves
over the Pace cleaner, the belt is pressed against a heavy-duty
scrubbing belt that's moving in the opposite direction. A tension device
on the conveyor keeps the two belts in constant contact. At one end of
the cleaning belt. a controlled water dispenser wets the belt surface
sufficiently to wash the conveyor surface and remove the spills. At the
other end of the tank unit is a built-in squeegee that squeezes out
absorbed solutions from the cleaning surface. The belt itself is
slightly wider than the conveyor and runs on two interior pulleys. The
drive pulley has an integral motor unit so no external belts are
"We only use a minute amount of water now," Razulis
reports. "and it's discharged directly into our waste lines." Adamchik
adds that the plant built a special drain to carry away the waste water.
It's been cleaned once, he says, but there hasn't been any need for
servicing the cleaner itself. The stainless-steel unit operates on
standard 110-v electric service. It could be fitted with a germicidal
drop unit; Seagram has found that water alone has been successful.
To further simplify operation, the engineers tied in
the controls for the cleaner with those of the accumulation conveyor.
Thus, when the conveyor is turned on. the cleaner automatically begins
to work too. Since there is no splash or water carryover, the cleaner
can run without any monitoring.
The most appreciated result, of course, is the more
consistent, trouble free operation of the cordial filling line as it
packages greater volumes of Vandermint and Cherry Suisse for
discriminating consumers around the country.
Reprinted from PACKAGING DIGEST May 1983 Copyright 1983 by Delta
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