Case study

Food & drink industry Bottling plant

Chivas Brothers
Chivas Brothers' success in its drive
to become the global leader in
Scotch's fast-growing premium sector
required a significant increase inproduction from the company's
Palletisation and Automatic Despatch
facility in Dumbarton on the outskirtsof Glasgow. The facility plays a key rolein the distribution of brands such as
Ballantine's, Beefeater Gin and Chivas
Regal 25 Year Old. A recently
completed project to upgrade thepalletising 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 siteand provide Chivas Brothers with anestimated 50% increase in output.

ChallengeSystemSolution

Reliable transport of fragile
product over distanceunderground

1,140 24v motorised rollers
manufactured by Itoh Denki

Energy efficient, run-on-demand
low voltage motorised rollers

Zero Pressure Accumulating logic
controls with built-in
communication links

Self-managing accumulation logic
prevents collisions and breakages

Increase production capacity
Energy efficiency

Adjustable speed and transferconfiguration
Smooth, low noise transport ofgoods on precision bearing rollers

Dynamic product buffering
automatically adjusts to
production throughput
Cost effective built-in controls
without the need for complex or
expensive PLC I/O modules

Case study Food & drink industry Bottling plant
The new conveyors transport different
sized 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 above
ground to the feed eight newpalletisers. The solution from Itoh
Denki was selected because it offeredsignificant energy savings overtraditional technology. It also
incorporated simple and reliable Zero
Pressure Accumulation controls which
ensure that the high value cartonsarrive safely at the palletisers, on
demand.
Itoh Denki's unique logic controls not
only prevent cases colliding, they also
manage the flow of cartons between
the bottling hall and the palletisers.
This provides a significant level ofproduct buffering which dynamicallyaccommodates the throughput
required by the palletisers or changes
in production output.
The controls work in conjunction witha photo-electric-cell in each conveyor
zone. Each zone comprises a single
motorised roller and several slaverollers.

T the next HB510
To
PLC

24 VDC

1 circuit board to each motor
T the next HB510
To

Drive zone

Conveyor section

The rollers are pitched to support thecartons and provide a clear and distinct
product space that segregates thecartons from one another. The
controller detects the arrival of cartonsin upstream zones from the production
line as well as monitoring the bufferingof cartons in downstream zones.
Providing the next section is clear andready to run, it will start the motorised
roller and transfer cartons from one
zone to the next. If a controller detects
the conveyor zone in front is occupied
and stationary it will hold product until
the downstream zone becomes free.
The system ensures a steady andregular flow of cartons is fed into theeight palletisers and maximises
throughput to the despatch area
without interruptions or breakages.

HB510PAt times of reduced throughput orchanges in production the motorised
rollers are automatically stopped by
the controllers and remain in standby
ready to start when signalled to do so.
This run-on-demand methodology
ensures minimum energy usage andmaximum efficiency with the use of
Itoh Denki's 24v Power Moller
motorised roller technology. PowerMoller motorised rollers and controls
can achieve an estimated 60%
reduction in energy use compared toconventional industrial drive solutions.

Zero Pressure Accumulation

Chivas Brothers, ProjectManager Stephen Trainor
describes the solution: “Thesystem is handling high value
goods and the loads are quitefragile, so the combination ofself-managed conveyors with
Zero Pressure Accumulation
provides very effective
protection for the valuable
throughput”.

ITOH DENKI EUROPE S.A.S.
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