Cost-effective solutions: semi-automatic packaging machinery
Automated packaging lines can be a costly undertaking, especially when a new business is being formed or production demands do not require uninterrupted filling, capping and labeling. In these situations, fully automatic packaging equipment can prove to be overkill, until the product or products catch on and production levels rise. Additionally, startups may want to invest capital in other areas, such as marketing and sales, to grow the business. When these and other issues are of concern, semi-automatic equipment can provide an efficient and cost-effective solution for packers.
1. Container cleaning equipment
While container cleaning equipment may not be found on all packaging lines, these machines are critical to a number of industries. In general, bottle washers and rinsers will be used in industries where products are ingested, injected, or come into contact with the body. Medications, foods, beverages, and the like that are concerned about contamination will almost always take advantage of some type of container cleaning machine. Typically, the rinsers and washers will be positioned just before the liquid filling machine to remove dust and dirt before introducing the product into bottles or other containers. Semi-automatic container cleaning equipment will require the operator to place the bottles to be cleaned in rinsing nozzles. These nozzles can use air, water, or another cleaning chemical to loosen and remove contaminants, sometimes using a vacuum to remove debris as well. Once rinsed, the machine operator will remove the clean bottles and transfer them to the bottle filler for product introduction.
2. Liquid filling machines
Semi-automatic liquid fillers can use the same filling principles as automatic equipment. This means that the semi-automatic machinery can handle thick and thin liquids, particulate liquids, hot fills and also sanitary products. Like container cleaning equipment, these machines will require the operator to position the bottles or containers before filling begins. Once the containers are in place, the operator will activate the fill cycle in some way, most commonly by stepping on a foot switch or pressing a finger switch. Semi-automatic filling machines can not only speed up the process over manual filling, but can also add consistency and reliability to filling. Once the filling cycle is complete, the operator will remove the bottles from the machine and move them to the next packaging phase, which will generally be the capping of the containers.
3. Capping machines
The type of semiautomatic capper used for any project will necessarily depend on the type of cap used. Semi-automatic equipment can be manufactured for screw caps, snap caps, ROPP caps, corks, and more. While some of these machines can speed up the capping process, the real benefit of semi-automatic machines comes from the constant adjustment of the closures. Manual capping of the product can lead to loose plugs, cross threading, and other problems simply from fatigue from the repetitive motion of the task. Capping machinery eliminates uncertainty by allowing repeatable and reliable machine movement. The operator’s task will differ slightly on different types of capping machines, but in general the cap will be placed on the bottle or container and the combination of the two will be placed in a nest position to allow the machine to tighten the closure. in the required way. Once securely closed, the bottles are removed from the machine and moved once more to the next packaging phase.
4. Labeling equipment
Labeling any bottle by hand is a daunting task for any canner. Not only will it quickly become a tedious task, but keeping labels straight and wrinkle-free can be challenging, to say the least. Semi-automatic labeling machines allow the operator of the equipment to simply place the bottle or other container in position. The labeler will then take over and apply the sticker when needed, using a sensor to see when a bottle is in place or a foot switch that allows the operator to start the labeling process once the container is ready. Semi-automatic labelers provide additional speed and a consistent, reliable application to manual labeling product.
At this point, a simple packaging system for rinsing, filling, capping, and labeling products and containers has been described. There are many other semi-automatic machines that can help in the packaging process. Additionally, semi-automatic equipment can often be combined into a small space or a single frame (often called a uniframe) to allow one or two operators to complete the entire packaging process. Many of the machines can be upgraded to allow for growth as production demands increase. These upgrades can include adding rinse heads or fill heads to a machine. But as an alternative, the semi-automatic equipment can be manufactured on the same framework as the automatic equipment and upgraded to work automatically in the future. These updates would normally include the addition of an indexing system and the addition or modification of the PLC and programming.
While automatic machinery may seem overwhelming from a financial perspective, packers should be aware that there are other solutions. These solutions can be a step toward full automation, enabling consistent, reliable, and often more efficient packaging without choking cash flow for new or smaller businesses.
