Phone: 305-805-8533 My Account Home Machines ▾ About Us Request a Quote Videos ▾ News & Articles Customer Support Cart Blog Acasi View All bottle unscrambler bottling line Conveyor InlineFillingMachine Liquid filler Machine Overflow filler plastic bottle handling September 10, 2019 Piston Filler - Model Trupiston When trying to figure out what filling machine to purchase for your company, look no further than our TruPiston filler. Available in a check valve or rotary valve design, the check valve is primarily used for water thin products as there is no area for the product to slip causing inaccurate fills. At the same time, where it thrives with thin products it’s not a preferred option to fill thick viscous products consistently and accurately. However, our rotary valve system can handle thin products with minimal accuracy issues on small fill volumes, while being able to rip through more viscous and chunky products with up to ¾” particulates for maximum efficiency. If you are dedicating one product to an entire line, or running a wide range of products and fill volumes Acasi’s electric ball screw piston filler is as ridged of a system as there is designed to handle production 24/7. If you would like to run products that range from 1 oz. – 1 gallon, Acasi’s TruPiston can handle it without any design changes to the standard machine (purchase the additional piston barrels). Via quick disconnect fittings, changing over nozzles for a new product can be completed ­­in a matter of minutes. Thin products that tend to string or drip at the end of the filling cycle can be handled using either our bottom close design, or an air knife which leaves a clean fill (preventing backups at a further point on the line) allowing for a smooth transition at each machine on the production line. Unlike pneumatic piston fillers that require air to drive the machine, Acasi’s TruPiston is driven by an electrically driven ball screw which allows more flexibility with product dispensing control. The product dispensing speed can be controlled from the beginning of the fill, all the way to the end. If you have a small fill volume or a wide mouth jar a pneumatic piston filler can experience air surges or “spikes” that create messy fills or a total catastrophe which in turn leads to downtime of the production line. With Acasi’s electrically driven ball screw, (for example) and to eliminate bad fill downtime caused by the air surges, the product can be filled at 100% speed for the first 90% of the total fill volume and then ramped down to the maximum dispensing speed while still producing a clean fill which allows for smooth production and a higher throughput. These ramp speeds can be stored in the HMI for quick and easy setup in the future. In addition to air surges causing bad or messy fills, they can also cause consistently inaccurate fills with constant changes in air pressure. No one likes to guess how much they are filling, so with Acasi’s Trupiston system, fill volumes can be accurately changed on the fly. You don’t need to stop the machine to adjust the dial on the back of the air cylinder, all you have to do is simply go to the HMI, select the fill volume and raise or lower it accordingly, and then immediately upon the next fill cycle, the volume is corrected. As mentioned above, the Trupiston filler is more versatile and efficient than pneumatic or air over oil systems. The system is designed with 304 or 316 SS, Teflon, Buna, and Viton polymers as wetted parts. The electric ball screw technology allows you to change dispensing speeds at different points of the fill cycle to produce a clean fill and maximize throughput as well as be able to change the fill volume on the fly directly from the HMI. This reduces downtime, and increases throughput. August 29, 2019 Bottle Unscrambler under utilization throughout the bottling industry After visiting more than one hundred manufacturing facilities I’m always surprised by the lack of bottle unscramblers being used in bottling and packaging production lines After asking if they would consider adding a bottle unscrambler most of the times I’m met with resistant with this claims: We have too many bottles, do too many changeovers Changeovers would take too long It’s a large investment I don’t have space Before disregarding this idea I would argue: We have too many bottles, do too many changeovers: A good bottle unscrambler would changeover faster than a capper and having your bottles being fed by a machine and not a human will increase your production offsetting x 10 cost of setup 2.Changeovers would take too long If you document your changeovers and use the indicators changeover should take no more than 10-15 minutes 3.It’s a large investment If you have one person working 8 hours per day feeding bottles a 35K bottles unscrambler would pay for itself in 1.5 years (just on labor costs), if you have 2 persons the payoff is less than 9 months 4. I don’t have space There are some places where you can simply not add any more equipment, otherwise the effort to put in the machine will pay for it self quickly If you are running production at least 30 hours per week at 30 bpm or more you should seriously consider adding a bottle unscrambler to your production line, not only will you save in labor costs but your production will increase by being more efficient on your bottle feeding. Bottle unscramblers don’t go to the restroom, chat with their buddies or work slower because of a bad hangover. One of my favorite manufacturing quotes by Henry Ford: "If you need a machine and don't buy it, you will ultimately find that you have paid for it and don't have it." April 14, 2019 bottle unscrambler › bottling line › Conveyor › InlineFillingMachine › Liquid filler › Machine › Overflow filler › plastic bottle handling › A friendly guide for some overflow inline filler machines troubleshooting When a customer buys a machine, a production line or a project: bottle unscrambler machine, conveyors, overflow or piston inline filler machine, inline capper machine, chuck capper, rotary tables, bottle gap transfers, bottle labelers, etc, all settings are made in our facilities to ensure the proper functioning of all systems. Once installed the machines in the final customer facility, the behavior of the production line can vary and obtain undesirable results in some systems, as a resulted to do a little adjusments to resolve these issues. The reason for this: little variations in the new environment: light, temperature, voltage, current, stability. quality of containers and caps, etc. Another variant of this same matter is when the customer decides to run new formats of bottles and / or caps, being necessary then, readjustments of settings. In addition, there may be cases of variations in the quality of the caps and containers, although they remain the same, they could affect the initial configurations of the line, even when the production line takes many hours with a stable behavior. I intend in this article to give you a guide to solve these problems. Some number of calls for technical service, are related to the mismatch of the sensitivity of the sensors, responsible for counting the inputs and outputs of bottles in the filling area. Next, a video of how to solve this problem, whenever necessary. Of course, problems may occur and one of the most common issues concerning to the GI 3300 Automatic Overflow Bottle Filler, is because the conveyor is not working. This may stop working for several reasons: When the function "Clean in place" is activated and the machine is turned off, this function is still active when turning the overflow inline filler machine on, preventing the conveyor and pump from working. Therefore, it is very important to check that function status. In order to work, the machine needs to have a logic, that logic is given by a system of sensors (proximity sensors and bottles input and bottles output sensors). In order the conveyor to work, the proximity sensor must be activated, which indicates the filler nozzles are up. For this, make sure the sensor is on. If the sensor is not, it can be due to two reasons: a) the sensor is not having contact with the main bar of the overflow filler machine, the sensor has been moved because it has been unscrewed by the movement of the nozzles , or b) the sensor is badly connected electrically, this prevents the PLC from receiving the signal from the sensor, therefore the PLC can not send the signal to the conveyor motor to turn it on. This sensor is connected to one of the inputs of the PLC (the PLC is the brain of the machine) and the logic of the operation is as follows: while the PLC is receiving a signal from the sensor, it will activate 2 outputs connected to the conveyor's driver. As a consequence, if the sensor is not properly connected to the input of the PLC (see the electrical drawing to know the number of the PLC input) the PLC will not be able to action the conveyor. March 11, 2019 bottle unscrambler › bottling line › plastic bottle handling › Improved production and utilization of available resources in bottling lines that run plastic bottles One of the productivity factors that is frequently overlooked by companies has to do with bottlenecks at the beginning of the production lines running plastic bottles. Often companies focus solely on automating the filling, capping, and labeling processes while relying on manual labor to load the bottles to the line. While this may be an acceptable setup initially, it may quickly become unsustainable on the long run, because of unreliability and the potential impact it will have on the company's overall production capacity. Adding an automatic bottle unscrambler to the line will significantly improve production and utilization of your available resources. Continue Reading > February 04, 2019 Capping problems As a manufacturer of inline capper and chuck cappers we have dealt with thousands of different bottles and caps and the reality is that capping is one the hardest part of of the bottling process. The main factors to take into consideration for better bottle capping results are: Choose the right Type of capping machine Inline cappers: This machines have the benefit of costing less, not needing change parts and being able to handle a wide range of caps including trigger sprayers (placed by hand). The main issue with this machines is that there are bottles and caps that have the tendency to cross thread, and difficult caps and/or bottles will have more issues on an in-line machine than a pick and place capper. Mots companies run this machines up to 100 bpm (bottles per minute) but some can run up to 250 bpm (depending on the bottle and cap design) VIDEO INLINE Pick and place chuck cappers: This machines work better on most containers and caps because the cap is transferred to the chuck and once it’s on the chuck it’s placed controlled, straight onto the container. If you pick the cap with the bottle you have the threads of the container picking up in different random positions so if the tolerances and/or the design is a bit tight or not forgiving you get cross threaded caps. This type of machines work great but have a high cost and require change-parts for each additional bottle and cap adding to the already high cost. For speeds above 200 bpm it’s the only effective solution VIDEO CHUCK Cap - bottle thread design Cap design: The cap design is critical, before you commit or buy large quantities make sure everything has been tested with your machines in your production floor. We’ve done projects where with the one bottle one cap we got 5% cross threaded caps and a different design, same sizes, we got 0.2% cross threaded caps The design of the bottle it’s also very important as well as the tolerances, specially with glass bottles. Also there are Designs that the thread on the bottle begins in the top edge and others have a small gap, on an inline machine this makes a big difference because when you pick the cap, if you have space the cap can sit properly before starting to thread Keep in mind each bottle and cap needs to be looked into, studied and tested to make sure it will work properly for your required speed, torque and consistency January 03, 2019 Changing over and adjusting handy, fast and easy on inline capper machines model Trucap by Acasi Machinery In the packaging business, specifically about bottle inline process (filling, capping, bottle handling), it is important that the machines be designed under fast, tool less, handy and easy concepts in order to get more profibility of invesment. Talking about capping process, Acasi Machinery has developed an inline capper machine, model trucap. This machine can be a simple tightener machine, or of course, you can get a complete automation system add a cap chute and a cap feeder, depending on the size of cap and bottle geometry. In a world where time is money, it is necessary to have a machine with tool less, easy, handy and fast changing over and adjusting concept, depending on whether you need to replace wear parts or need to adjust to a disk or belt parameters with the machine running. That's why Trucap capper machine by Acasi Machinery has a Value Added. We are going to talk first, about replace process on parts susceptable to wear. At this point, it is important that you are able to change a spare part in a minimun time and minimum simple hand adjusments in order to reduce a machine stop time. Please take a look at the pictures on the bottom where I pretend to show a sequence of steps to uninstall a disk assembly: After many hours of operation, the orange disk on a spindle capping systems are susceptible to wear. Therefore, eventually you will need to replace these orange disks. Just removing a pin, you can uninstall a complete capping disk or spindle assembly. On the other hand, it is very common that you will need to change the physical values set on your capper machine depending on certain cap geometry or even depending on different bottles diameters. If you need to switch to different cap or bottle, could be a high undesired wasted of time, if you do not have the right machine. Please take a look at a short video clicking this link. Trucap capper machine has an easy and handy solution, by using front knobs with position indicator for easy setup, to adjust the height and width of the gripper belts which keep the bottles in the right and stable position for capper process. Besides, the front doors have convenient holes, in order to avoid opening doors, and to adjust the width of the capping disks or spindles, with the purpose to get the right set for your cap. December 03, 2018 A practical solution for small bottle handling A gap transfer (model GT16) is an elegant and cost-effective solution for difficult to handle bottle transitions. Continue Reading > 1 2 Next » Mailing List Sign up to get the latest on sales, new releases and more … Main Menu Home Machines About Us Request a Quote Videos News & Articles Customer Support Videos Filling Machines Videos Labeler Videos Filling Rotary Videos Inline Capping Machines Videos Chuck and Push Cappers Videos Bottle Unscramblers Videos Bottle Reject Videos Bottle Cleaners Videos Rotary Tables Videos Multiple Machines Videos Technical Videos Social Facebook YouTube LinkedIn Instagram Blog Acasi RSS © 2021 Acasi We run on a secure payment gateway