Dry lubrication applied to Newamstar high-speed light bottle combibloc production line.
In order to ensure the stability of PET bottled drink production line and to reduce the abrasion of PET bottle conveying chain, most of the beverage manufacturers adopt chain lubricant for lubrication. Usually, friction factor is less than 0.15. For a long period, vast manufacturers use wet lubricating method. Wet lubrication means to mix the lubricant and water according to certain proportion through distribution system and then spray to the conveying chain. As this lubricating method has advantages like good performance and easy maintenance, it is widely used in beverage and beer industry.
In recent years, with the operation cost of beverage manufacturers increasing constantly, and with their environmental awareness enhancing continuously, defects like high water consumption, high requirements of water quality and pressure, environment pollution of traditional wet lubricating method are emerging increasingly.
Dry lubrication directly adopts stoste for the lubricating. No need of water mixing. Advantage of dry lubrication is its good performance and low water consumption. Besides, antibacterial effect is better as no foam will overflow to the floor. Dry lubrication technology is becoming more and more mature and be accepted by the market after several years’ testing. Below data is concluded by analyzing two lubricating methods – wet and dry of the 43,200BPH light bottle combibloc production line of Panpan Group. Lubricating system and chemicals are supplied by Beijing Anncore Biotechnology Co., Ltd.
1. Friction factor.
Take sample bottle and measure its dynamic friction force(g) by tension meter and then divide bottle weight.
Dry lubrication usually adopts like glycerin, organosilicone etc. as raw material. It has better lubricating performance than wet lubrication (main constituents of wet lubricant are aliphatic amines or fatty acid) as shown in diagram 1. Time control system is installed in every section of dry lubrication, thus to control every section of chain precisely and to set different spraying time for different sections of chain, while time control system of wet lubrication is grouped – 4-7 sections of chains as one group. For example, by using dry lubrication method, spraying time of chains before labeling (multiple rows to single row with high speed) can be adjusted longer separately as this area requires higher lubricating performance.
2. Water consumption.
Dry lubrication directly adopts stoste for the lubricating. No need of water dilution. Water consumption is zero.
Wet lubrication requires mixing of lubricant and water. Dilution proportion usually is about 1:500 (lubricant : water). If whole line is equipped with 196 nozzle, water consumption of one nozzle is 0.12L/min, spraying and stopping time is 30s : 30s, water consumption of one month is 406. 4T (suppose machine runs 24 days per month).
3. Influence to surrounding environment.
Wet lubrication use water as spraying force. Foam is easy to be produced because of formula problem. Foam will overflow to floor to damage the sanitary of the workshop.
While dry lubrication directly adopts stoste for the lubricating. No need of water dilution. Spraying time is short with lower consumption. Besides, no foam will be generated, thus no influence to the workshop.
Seen from above data, it can be concluded that dry lubrication has advantages over wet lubrication in the aspects of friction factor, water saving, sanitary keeping. Besides, dry lubrication performance is better. It can reduce the load of the conveyor. It is indicated from the statistic that lubricating performance can be increased by 50-100%, motor power can be decreased by 20%. From environmental protection aspect, constituent of dry lubricant is easier to be degraded besides it water saving advantage.
There is no doubt that dry lubrication technology will be widely applied to PET bottled beverage production line including high-speed combibloc, helping beverage manufacturer develop better and faster.
NEWAMSTAR HIGH-SPEED BLOWING-FILLING-CAPPING COMBIBLOCK
Newamstar High-speed Blowing-filling-capping Combiblock combines the blowing system, filling system and capping system in one integrated system, reducing several intermediaries suchas transmission, empty bottle handling and storage processes, which improves packaging hygienic condition and reduces packaging ross-contamination so as to improve the overall operating efficiencybut lower the energy consumption, thereby reduces the overall production cost of enterprises.
- Product Range: Production capacity from 12,000 BPH to 80,000 BPH.
- Applications: It is applied to PET bottled pure water, carbonated soft drink, juice, liquid dairy, liquid condiment and household & personal care products, etc.
Stable infrared ray heating system and independent heat balance device ensure the stable temperature of the preform, even color of the bottle and increase of the output.
Special designed twice-blowing system can monitor the pressure in each mold in order to provide accurate real-time parameter for operator. It is easy for the operator to adjust the parameter and ensure the stability of bottle forming.
High-speed and high-accuracy diaphragm type filling valve: Equip air back channel which is separated from liquid carousel, by which, the air replaced from the PET bottle won’t enter liquid carousel to avoid second pollution. Equip cleaning dummy bottles which can realize online CIP.
Sanitary and washable capper：Optimized cam surface design ensures the minimum
impact force of the capper .Bottle discharging starwheel is screwing decently, so it is unnecessary to adjust the conveyor height during bottle format change.
Driven by innovation and win the market by quality!
Newamstar has focused on liquid packaging industry since from its establishment. Taking innovation as guide and basis, we have been forging ahead constantly.
As an outstanding company in China high-end equipment industry, Newamstar has built a dimensional product system gradually including beverage, milk, alcohol, condiment and daily used chemicals. We have won many innovative “China First” for various products. All these achievements and milestones will be fixed and memorized in the long history of Newamstar.
INTELLIGENT STEREOSCOPIC WAREHOUSE SYSTEM: THE FIRST CHOICE OF BEVERAGE FACTORY TO UPGRADE THE MODERN WAREHOUSING AND LOGISTICS!
In recent years, with the increasing of automation and production capacity of liquid food packing line, contradictions between inventory and production capacity have become increasingly prominent. At the same time, with the increase of land cost and labor cost,traditional discrete model of warehousing and logistics using single logistics equipment or personnel to carry out the transportation of product and raw materials has been outdated.
With the deepening of “industry 4.0” and “Internet +” concept, the Chinese industry is transforming from the traditional labor-intensive to the industrial automation, and the traditional management mode based on people is turning to computer-based Information and modern management. Intelligent equipment represented by robot and a new generation oflogistics model with the function of data collection, management and data tracing is being more widely used in the market.
As the Chinese leader in the field of liquid packaging, Newamstar accumulated rich experience in long-term development. By industry research, product technology development and the integration of industry resources over one year, Newamstar introduced the concept of “Internet +” into the production line followed by the pace of “Industry 4.0”. On the basis of rising the capacity and stability of liquid packaging production line, Newamstaroptimized the structure of production lines and improved the level of automation of the production line by reducing the cost, and improving the quality and efficiency.
- Goods transition and storage – high rise shelf, tray and container.
- Check in & out device – palletizer.
- Check in & out distribution system – roller and chain conveyor, distributing vehicle, lifter, etc.
- WCS control system – includes check in-out device controlled by computer, distribution system, various kinds of inspection and safety device controlled by electricity.
- WMS warehouse management system – warehouse account management, data analyzing, goods site arrangement, device operation and warehouse storage display, etc.
A double extension tunnel stacking machine is adopted in the projects of“Moon over a Fountain Co. Ltd”, which achieve an effective balance between capacity and efficiency by improving space utilization and flexibility of warehousing in a limited space. The production line is connected with the warehouse directly, so a lot of material transfer links was saved. With advance internet technology, it realizes the resources and data sharing and connection between the ERP(enterprise resource management system), MES (manufacturing execution system) and WMS (warehouse management system) to reduce the mistakes and speed up access of the goods. Compared with the traditional discrete warehouse, Intelligent stereoscopic warehouse system can save the cost of land investment, reduce labor intensity, improve the working environment and reduce labor costs, finally improve the production efficiency and the level of modern management by making packaging and storage systemIntegrated, automated and intelligent.
In 2015, with excellent R&D design team and processing advantages of equipment manufacturing, Newamstar completed the development of automated warehouse system with tunnel stackerand RGV rail transport trolley. In the same year, Newamstar successfully presented it on CBST exhibition in Shanghai, and received wide attention from lots of companies in the industry. In 2016, automated material transport under special circumstances is solved by researching and developing non-rail AGV transport trolley. Through the introduction of advanced visual logistics simulation software FlexSimand excellent simulation designers, we can make simulation test in the project planning process, and do all kinds of system analysis and engineering verification for the model to get the final optimized the design. It can also quickly confirm the logistic equipment solution, further verify the feasibility of the project, provide improving and management basic data for the system, and reduce operating costs of production enterprises.
Currently, Newamstar are upgrading internal logistic systembased on stereoscopic warehouse system, will build automated logistics system by using AGV non-rail Intelligent trolley to distribute the raw materials, and create a new automated management system with the product lifecycle management, process management and information management.
New age, a new chapter, a new dream. With the evolution and promotion of intelligent stereoscopic warehouse system, it will help beverage manufacturers to clarify and refine requirements, quantify data target and accuracy control of the production process, and finally help to realize the intelligent, automation and modernization of plant.