In today’s highly competitive global markets, users of filling machines know that every drop counts. As they tighten the reins on wastage and look to maximize utilization, these users seek out OEMs who are able to deliver the highest performance with the greatest precision. These qualities are particularly critical in rotary gravity fillers, where weight measurements must compensate for vibrations and centrifugal forces and the timing of dosing nozzles must be extremely precise. Span Filling Systems has become a prominent name in the packaging industry by offering a range of filling and capping machines with the outstanding automation performance and precision users have come to expect from B&R.
Laboratories need acids and chemicals; automobiles, pharmaceuticals, drycleaners and adhesives need solvents; printing presses need ink; buildings need paint. Before these day-to-day items can be transported, stored and used, they must first be packaged. Span Filling provides liquid packaging solutions forindustries ranging from dairy to pharmaceutical, personal hygiene to paint and lubricants to beverages. Known for its quality solutions for high-speed production, this packaging industry leader relies on B&R’s impeccable design and technology to outclass market needs for net weight liquid gravity filling in all types of containers – with a level of precision that makes every drop count.
Synchronized precision in motion
the most innovative products available on the market. The modular design makes it flexible and
very easy to use.
Span Filling offers in-line fillers that can be adapted to specific customer requirements. To meet the stringent market demands of consistency, Span Filling had to think of a solution to deliver higher speed with increased accuracy. This gave birth to the idea of a rotary gravity filling machine. With their speeds synchronized, a conveyor feeds bottles to a rotary disc so that each bottle fits into a specific position. The filling mechanism is mounted on a second rotary disc, with a nozzle aligned directly above each bottle. The filling process is completed as the station rotates 180 degrees, after which the outfeed conveyor carries the bottles on to the capping process. Fill quantity is determined by weight, which is measured by load cells that communicate with robust B&R hardware. The drives for the conveyor and two rotary discs have to be perfectly synchronized to avoid system failure. ACOPOS servo drives from B&R ensure precise control with easy synchronization and guarantee that the required performance levels are met.
A solution for every design obstacle
measurement has been a major
factor in helping Span Filling achieve its development goals and has played a significant role in our
continued growth.” Kumar Darara, managing director, Span Filling Systems
The most critical design challenge was achieving accurate weight reading susing highly sensitive equipment mountedona continuously rotating station. B&R’s highly efficient weight measurement solution made it the clear choice for Span Filling’s application. The input filters onboard B&R’s X20AI1744 module provided a cost-effective standard solution for the strain gauge cell that cancels out false readings caused by centrifugal forces and mechanical vibrations.
The application also demanded a design able to accommodate both the control and feedback systems on the rotating structure. With the filling nozzle controls and weight sensors in constant motion, the hardware would be subjected to relentless vibration. B&R’s X20 series of control and I/O modules handled the situation with ease.
Communication was another obstacle, as it would have to link the rotating components with the HMI panels and other stationary field devices. B&R’s Power PanelHMI –which provides visualization and operation ofthe entire system– and other field devices communicate with the X20 controller via a slip ring, providing maximum performance with minimum wiring.
Accuracy down to 0.1%
The main objective for the machine was to control the process at an optimal speed that would allow increased production rates while maintaining the necessary precision. The innovative closed loop control algorithms successfully achieved a maximum production rate of 40 containers a minute filled to 5000 g with an accuracy of +/- 1 g.
After years ofreliable hardware, software and service from B&R, Span Filling has grownto rely onthe partnership as a key component ofits continued growth. The effective merging of mechanical design with electronic control was vital to the successful completion of this project. A joint effort from Span Filling and B&R has proven to be a formula for success.
