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Challenge:

Global brewer requires data and insight for container light weighting project

At the onset of a major light weighting project, a global brewing company sought a qualified source to audit their packaging filling lines and evaluate potential loads. Their main priority was to understand the facility’s ability to run light weight containers such as aluminum cans and non-returnable glass bottles.

 

The requirement specifically outlined shock, pressure and other mechanical forces such as top load for the audit’s focus. These forces represented the major factors that needed be understood and controlled to minimize damage to the new container designs while also maximizing processing capacity. Glass breakage was a particular concern.

 

A major outcome of the audit was to identify and recommend appropriate corrective actions.

Solution:

Smart in-line sensors used to evaluate potential high-risk areas when processing light weight containers

ShockQC, PressureQC and VerticalQC used to evaluate potential high-risk areas when processing light weight containers.

 

After evaluating the available options, the brewer and auditing partners selected the Masitek suite of smart in-line sensors as the measurement solution for the project. The smart sensor replicas were designed to match the brewer’s new light weight container designs for both aluminum cans and glass bottles.

 

A combination of ShockQC, PressureQC and VerticalQC sensors were deployed to deliver on-site measurements of friction, scuffing, pressure, impact and vertical load. Mechanical forces were measured throughout the filling process including all conveyors and most machines.

 

Used in combination with the solution’s wireless location tracking beacons, the auditing team was able to precisely locate areas of the packaging filling lines with the highest potential risk for light weight containers. When combined with the auditor’s experience and process, the team was able to deliver a comprehensive report for the design team and also identify areas of concern in the line for the future light weighted container.

Sensor data precisely located areas of the packaging filling lines with the highest potential risk for light weight containers