Case study Food & drink industry Bottling plant Challenge Solution System C hivas Brothers' success in its drive to become the global leader in Scotch's fast-growing premium sector required a significant increase in production from the company's Palletisation and Automatic Despatch facility in Dumbarton on the outskirts of Glasgow. The facility plays a key role in the distribution of brands such as Ballantine's, Beefeater Gin and Chivas Regal 25 Year Old. A recently completed project to upgrade the palletising and conveyor systems included a significant quantity of motorised rollers and Zero Pressure Accumulation controls from Itoh Denki. The system is designed to ensure maximum production from the site and provide Chivas Brothers with an estimated 50% increase in output. Reliable transport of fragile product over distance underground Increase production capacity Energy efficiency 1,140 24v motorised rollers manufactured by Itoh Denki Zero Pressure Accumulating logic controls with built-in communication links Adjustable speed and transfer configuration Smooth, low noise transport of goods on precision bearing rollers Energy efficient, run-on-demand low voltage motorised rollers Self-managing accumulation logic prevents collisions and breakages Dynamic product buffering automatically adjusts to production throughput Cost effective built-in controls without the need for complex or expensive PLC I/O modules Chivas Brothers
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Case study Food & drink industry Bottling plant
Challenge SolutionSystem
Chivas Brothers' success in its driveto become the global leader in
Scotch's fast-growing premium sectorrequired a significant increase inproduction from the company'sPalletisation and Automatic Despatchfacility in Dumbarton on the outskirtsof Glasgow. The facility plays a key rolein the distribution of brands such asBallantine's, Beefeater Gin and ChivasRegal 25 Year Old. A recentlycompleted project to upgrade thepalletising and conveyor systemsincluded a significant quantity ofmotorised rollers and Zero PressureAccumulation controls from Itoh Denki.The system is designed to ensuremaximum production from the siteand provide Chivas Brothers with anestimated 50% increase in output.
Reliable transport of fragileproduct over distanceunderground
Increase production capacity
Energy efficiency
1,140 24v motorised rollersmanufactured by Itoh Denki
Zero Pressure Accumulating logiccontrols with built-incommunication links
Adjustable speed and transferconfiguration
Smooth, low noise transport ofgoods on precision bearing rollers
Energy efficient, run-on-demandlow voltage motorised rollers
Self-managing accumulation logicprevents collisions and breakages
The new conveyors transport differentsized cartons containing a variety ofbottle sizes, from eight existingproduction lines in the Clyde bottlinghall to a completely new palletisingsystem. Cases leave the bottling hall oneight separate conveyor lines at speedsof up to 60 cases per minute. All eightlines then travel underground forapproximately 100m and aroundseveral bends before returning aboveground to the feed eight newpalletisers. The solution from ItohDenki was selected because it offeredsignificant energy savings overtraditional technology. It alsoincorporated simple and reliable ZeroPressure Accumulation controls whichensure that the high value cartonsarrive safely at the palletisers, ondemand.
Itoh Denki's unique logic controls notonly prevent cases colliding, they alsomanage the flow of cartons betweenthe bottling hall and the palletisers.This provides a significant level ofproduct buffering which dynamicallyaccommodates the throughputrequired by the palletisers or changesin production output.
The controls work in conjunction witha photo-electric-cell in each conveyorzone. Each zone comprises a singlemotorised roller and several slaverollers.
The rollers are pitched to support thecartons and provide a clear and distinctproduct space that segregates thecartons from one another. Thecontroller detects the arrival of cartonsin upstream zones from the productionline as well as monitoring the bufferingof cartons in downstream zones.Providing the next section is clear andready to run, it will start the motorisedroller and transfer cartons from onezone to the next. If a controller detectsthe conveyor zone in front is occupiedand stationary it will hold product untilthe downstream zone becomes free.The system ensures a steady andregular flow of cartons is fed into theeight palletisers and maximisesthroughput to the despatch areawithout interruptions or breakages.
At times of reduced throughput orchanges in production the motorisedrollers are automatically stopped bythe controllers and remain in standbyready to start when signalled to do so.This run-on-demand methodologyensures minimum energy usage andmaximum efficiency with the use ofItoh Denki's 24v Power Mollermotorised roller technology. PowerMoller motorised rollers and controlscan achieve an estimated 60%reduction in energy use compared toconventional industrial drive solutions.
Drive zone
Conveyor section
PLC 24 VDCToTT the next HB510
ToTT the next HB5101 circuit board to each motor
Chivas Brothers, ProjectManager Stephen Trainordescribes the solution: “Thesystem is handling high valuegoods and the loads are quitefragile, so the combination ofself-managed conveyors withZero Pressure Accumulationprovides very effectiveprotection for the valuablethroughput”.