New KHS Innocheck LFL Empty Bottle Inspector for the Beverage
Industry
New KHS Innocheck LFL empty bottle inspector
Reliable, Hygienic, Simple, and Virtually Maintenance-free New
KHS Innocheck LFL empty bottle inspector fulfills visions
Flawless bottles for optimum filling processes - a must for all
bottling operations. In this connection, reliable inspection
equipment is very simply indispensable, above all for refillable
bottle lines. Dependable inspection equipment means detecting
and rejecting bottles that do not meet the specified quality
requirements. This includes not only damaged bottles and bottles
containing residual liquids or foreign substances but also those
with visible flaws such as signs of apparent wear.
With its newly developed Innocheck LFL empty bottle inspection
system, KHS relies on a system that successfully combines
simplicity, hygienic design, and maximum inspection assurance.
Innovative KHS inspection equipment very specifically follows
the inspection technology used in the pharmaceutical industry, a
sector of the market well known for its maximum inspection
demands and a policy of "reliability without compromise".
Reduced conversion effort for bottle changeover The Innocheck
LFL is a linear empty bottle inspector. In comparison to the
rotary-type machine, the main compelling features of a linear
inspector include low cost of investment as well as reduced
mechanical changeover effort required for changing bottle styles
at the same level of inspection reliability. Unlike rotary-type
machines, linear empty bottle inspectors require no changing of
bottle guide parts. The only mechanical readjustments necessary
involve turning a handwheel to adapt the transfer lane to a
position stored in memory. All other necessary resettings are in
a computer program ready for automatic retrieval at the push of
a button.
Consistent hygienic design The Innocheck LFL uses two belts
running in parallel to guide the bottles. These plastic belts
are surface-sealed and therefore easy to clean. No belt pulleys
are used; a decision was made very specifically in favor of
hygienic-design V-belts.
The Innocheck LFL principally combines all key characteristics
of hygienic design. The open-type machine construction with its
smooth surfaces and few corners allow easy access for thorough
machine cleaning. The hygienic design is enhanced further by
sloped runoff surfaces and the consistent use of stainless steel
materials. Outputs of up to 60,000 bottles/h.
The Innocheck LFL is exceptionally versatile; it can be
integrated in any - glass as well as plastic - bottling line and
is capable of inspecting bottles with a control excursion at an
output of up to 60,000 bottles/h. It provides capabilities for
complete bottle inspection including bottle mouth inspection,
outside bottle wall inspection, inside bottle wall inspection,
bottle base inspection, and residual liquid checking.
Outer sidewall inspection The first inspection step of the
Innocheck LFL: inspection of outer sidewalls. A light source
illuminates the surface of the bottle on one side of the bottle
while a reflective optical system of a camera mounted on the
opposite side records the image of the sidewall. Besides the
sidewall inspection, this inspection station is capable of
handling an additional function that involves measuring the
format of each individual bottle. Any bottles not satisfying the
prespecified production criteria are reliably rejected even
before they reach the belt conveyor. In the high-capacity range
of more than 40,000 bottles/h, a separate format check is
installed upstream.
Belt drive for exact speed control 'Good' bottles are
subsequently held between two belts running in parallel.
Servomotors drive these belts at different rates of speed. Using
servomotors means hygienic design, low maintenance, and
extremely precise speed control. Maximum-precision speed control
of each belt is necessary in order to ensure that each bottle is
rotated to an exactly defined angle between the first sidewall
inspection and the second sidewall module located immediately
downstream to the belt conveyor. This is essential in turn to
accomplish complete inspection of the sidewalls of each bottle
including the bottle contact points.
The bases of the bottles do not touch down as they are conveyed
by the belts. One of the prerequisites for further necessary
inspections. Inspection of the inner sidewalls and bottle bases
and the residual liquid check follow the bottle mouth
inspection. The light sources for checking bottle mouths are
located above the bottle and those used for inspecting inner
sidewalls and bottle bases and the residual liquid check are
mounted underneath the bottle. Using high-resolution CCD cameras
means high-noise-immunity digital image transmission.
Bottle mouth check The bottle mouth inspection involves
inspecting the sealing surfaces. The ring flash of the sealing
surface inspection flashes light on the container mouth from
above; the reflected image is recorded by a CCD camera and
subsequently analyzed. This method detects flaws such as chipped
sealing surface areas, shell fragmentation at the bottle mouth,
faulty threads, and scuffing on the sealing surface.
Inner sidewall inspection The size of the inspection area is
determined by the geometry of the bottles to be inspected.
Nearly 100 percent of the inner sidewalls can be inspected for
those bottles with soft transition points in the neck area. This
makes is possible to reliably detect flaws hidden behind
lettering or extreme scuffing that remain concealed to the outer
sidewalls inspection. Detection of transparent blemishes is
another subject area associated with the inner sidewall
inspection. Example: remnants of plastic film still contained in
the bottle.
Bottle base inspection The bottle base inspection divides the
bottle base into zones that can be defined using various
algorithms and separate sensitivities. Inspecting the bottle
base areas of plastic bottles additionally involves checking for
stress cracks.
Infrared and high frequency residual liquid check is standard
When it comes to checking for residual liquids, the Innocheck
LFL relies on two different methods. Maximum reliability is the
motto in this instance as well. The infrared residual liquids
check detects all substances that absorb infrared light. The
high-frequency residual liquid check uses various relative
permittivities to differentiate liquids. This method reacts
particularly sensitively to traces of caustic in bottles. Both
of the different physical methods of liquid measurement
harmonize outstandingly and represent a basic function of the
Innocheck LFL.
Selective separation of containers The second outer sidewall
inspection in the Innocheck LFL that guarantees complete
inspection of all sidewalls is followed by separation of
inspected bottles in various bottle diversion channels. These
channeled-out bottles are differentiated in production bottles
and rejection bottles. It is also possible however, to
redistribute these channeled-out bottles further. Such as dirty
bottles to be returned to the bottle washer, defective bottles
for immediate waste disposal, and test bottles diverted to a
separate accumulation segment.
Test bottle cycles assure production quality Test bottles are
used within predefined cycles to repeatedly test the inspection
machine and ensure that it is in proper working order. For this
purpose, bottles with defined flaws are introduced to the
process, run through the machine, and subsequently analyzed to
determine if all faulty areas are detected. Special markings on
the test bottles ensure that they are also channeled out to the
test bottle segment provided. The expected test results are
always immediately compared with the actual test results. The
test bottle program fulfills the user's obligation to assure
production quality. It is recommended to run the test bottle
program at the beginning of production operation and after
changing shifts and machine operating personnel. The test bottle
inspection intervals can be optionally stored automatically in
the system.
Suitable for refillable and non-refillable bottle lines Although
the Innocheck LFL has been designed primarily to inspect
refillable bottles, it is capable of inspecting variously sized
and shaped bottles made of diverse materials.
It is also feasible to use the Innocheck LFL to inspect
non-refillable containers - glass bottles in particular.
Possible problem areas arising with non-refillable glass bottles
involve damage incurred during the bottle manufacturing process
and damage sustained during shipment, e.g. bottles containing
glass threads and damaged bottle mouths.
High ease of use With the Innocheck LFL, a system is available
to the beverage trade that meets maximum demands for safety.
Each inspection function reliably and accurately assesses the
bottle quality. The system stops automatically should one of the
inspection functions fail. The user is immediately provided the
relevant information and a corresponding error report. The
Innocheck LFL is designed for exceptional ease of use. All
required system parameters are displayed on a monitor simply and
clearly arranged. For reasons of safety, a hierarchical password
structure checks the access authorizations of operating
personnel.
Optional direct online support Another important advantage of
using the Innocheck LFL: utilization of ReDiS. ReDiS means
Remote Diagnostic Service and on request provides accurately
detailed analyses of all machine components from KHS
headquarters as well as direct assistance online.
It is advisable to implement ReDiS to take care of, among other
things, any expected reprogramming. If the customer intends to
process a new bottle size in the Innocheck LFL for example, then
the related electronic changeover work can be programmed from
KHS headquarters after a ReDiS communications link has been
established. Likewise feasible: downloading updates via ReDiS.
Besides increased machine availability through quick online
support and the related greater competitiveness, ReDiS also
offers another very significant advantage: tremendous savings
potential. In most cases, the presence of a service technician
on site is not necessary due to selectively employed online
support.
Well thought-out down to the last detail Conclusion: With its
Innocheck LFL, KHS launches an empty bottle inspection system to
the market that has not only been well thought-out down to the
last detail but also offers maximum safety and at the same time
exceptional ease of operation and flexible design. The hygienic
concept and high serviceability of the system are additional
compelling aspects.
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