Manufacturing system

Abstract

The present invention provides a manufacturing system including a container manufacturing line for manufacturing containers and a filling line for filling the containers with a filling, wherein the container manufacturing line is coupled with the filling line and containers manufactured in the container manufacturing line are supplied to the filling line. The container manufacturing line may include a first speed control unit for controlling the manufacturing line speed according to the filling line speed of the filling line. The first speed control unit may change the manufacturing line speed of the container manufacturing line according to variations in the number of containers in a predetermined process in the filling line.

Description

Technical Field

[0001] The present invention relates to a manufacturing system.

Background Art

[0002] Patent Document 1 discloses that a beverage can manufactured in a can manufacturing factory is filled with contents in a beverage can manufacturing factory. [Prior Art Document] [Patent Document] Patent Document 1 Japanese Unexamined Patent Application Publication No. 2019-25521 Problems to be Solved

[0003] Conventionally, since the container manufacturing line and the filling line are in different factories, it has been difficult to manage the container manufacturing line and the filling line in a consistent manner. General Disclosure

[0004] In order to solve the above problems, in a first aspect of the present invention, there is provided a manufacturing system including a container manufacturing line for manufacturing a container and a filling line for filling the container with a filling material, the container manufacturing line being connected to the filling line, and the container manufactured by the container manufacturing line being supplied to the filling line.

[0005] The container manufacturing line may include a first speed control unit for controlling the manufacturing line speed according to the filling line speed of the filling line.

[0006] The first speed control unit may change the manufacturing line speed of the container manufacturing line according to the change amount of the number of containers in a predetermined process of the filling line.

[0007] The first speed control unit may adjust the manufacturing line speed so as to match the filling line speed.

[0008] The first speed control unit may switch between a first manufacturing line speed corresponding to the filling line speed and a second manufacturing line speed higher than the first manufacturing line speed.

[0009] The filling line may include a second speed control unit for controlling the filling line speed according to the production line speed of the container production line.

[0010] The second speed control unit may adjust the filling line speed to match the production line speed of the container production line.

[0011] The manufacturing system may maintain a constant overall line speed of the container production line and the filling line by changing the line speed of at least one of the container production line or the filling line.

[0012] The manufacturing system may distribute to the filling line when the ratio of the filling line speed of the filling line to the production line speed of the container production line is 0.25 or more and 1.80 or less.

[0013] The manufacturing system may include a first accumulation step of accumulating containers between the container production line and the filling and sealing step of the filling line.

[0014] The manufacturing system may distribute to the first accumulation step when the production line speed of the container production line is faster than the filling line speed of the filling line and the number of containers in the filling line exceeds a predetermined ratio to the capacity of the filling line.

[0015] The manufacturing system may include a second accumulation step of accumulating containers between the container production line and the filling and sealing step, with a larger accumulation capacity than the first accumulation step.

[0016] The manufacturing system may be accumulated in the second accumulation step when the production line speed of the container production line is faster than the filling line speed of the filling line and the number of containers in the filling line exceeds a predetermined ratio to the capacity of the filling line and a predetermined ratio to the accumulation capacity of the first accumulation step.

[0017] The manufacturing system may determine the distribution destination of the containers from the container production line according to the line stop times of the container production line and the filling line.

[0018] The manufacturing system may include a partition that covers the periphery of a predetermined process.

[0019] The partition may achieve a cleanliness class different from that of other processes.

[0020] The partition may be provided in at least a part of the processes of the container manufacturing line.

[0021] The partition may be provided in at least a part of the processes of the filling line.

[0022] The manufacturing system may include an inspection process between the container manufacturing line and the filling and sealing process of the filling line.

[0023] The manufacturing system may be provided in front of the container manufacturing line and may include a preliminary material manufacturing line for manufacturing a preliminary material for manufacturing the container. The preliminary material manufacturing line may be connected to the container manufacturing line, and the preliminary material manufactured on the preliminary material manufacturing line may be supplied to the container manufacturing line.

[0024] The preliminary material manufacturing line may include a third speed control unit for controlling the preliminary material manufacturing line speed according to the manufacturing line speed of the container manufacturing line and the filling line speed of the filling line.

[0025] The cleanliness class of the preliminary material manufacturing line may be higher than that of the container manufacturing line.

[0026] The container may be a metal can.

[0027] The container manufacturing line or the filling line may include a label attaching process for attaching a label printed on the container.

[0028] The container manufacturing line may include an identification information providing process for providing individual identification information for identifying an individual of the container. The filling line may identify the container using the individual identification information.

[0029] Note that the above summary of the invention does not enumerate all the features of the present invention. Also, sub - combinations of these feature groups can also be inventions.

Brief Description of the Drawings

[0030]

Figure 1A

Figure 1B

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Figure 4B

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Embodiments for Carrying Out the Invention

[0031] Hereinafter, the present invention will be described through embodiments of the invention. However, the following embodiments do not limit the invention according to the claims. Also, not all combinations of features described in the embodiments are essential for the solution means of the invention.

[0032] FIG. 1A shows an overview of the configuration of the manufacturing system 100. The manufacturing system 100 includes a container manufacturing line 10 and a filling line 20. Although an example where the container 200 is a metal can may be described, the container 200 is not limited to a metal can.

[0033] The container manufacturing line 10 manufactures the container 200 from a preliminary material 210. When the container 200 is a metal can, the container manufacturing line 10 manufactures the container 200 by shaping the preliminary material 210 into the shape of a metal can. The container manufacturing line 10 may print any image on the container 200. The image may be a symbol, sign, character, number, figure, color, or a combination thereof, or a design constituted by combining these. Specific processes of the container manufacturing line 10 will be described later.

[0034] The container 200 is for filling a filling material in the filling line 20. The container 200 may be a can, a PET bottle, a bottle, a pouch, a box, a paper pack, a cup, or the like. The container 200 only needs to be able to accommodate the filling material filled in the filling line 20. The shape and material of the container 200 are not particularly limited.

[0035] The preliminary material 210 is a material used for manufacturing the container 200. When the container 200 is a metal can, the preliminary material 210 may be a plate-shaped coil for generating the container 200. Both sides of the coil may be laminated. When the container 200 is a PET bottle, the preliminary material 210 may be a preform used for manufacturing the PET bottle. Further, the preliminary material 210 may be an article such as paper, a resin sheet, or a film.

[0036] The filling line 20 fills the container 200 with a predetermined filling material. The filling line 20 may attach a lid to the container 200 filled with the filling material. When the container 200 is a metal can, the filling line 20 manufactures a beverage can filled with a beverage in the metal can. The specific process of the filling line 20 will be described later.

[0037] In the manufacturing system 100 of this example, the container manufacturing line 10 is connected to the filling line 20, and the container 200 manufactured on the container manufacturing line 10 is supplied to the filling line 20. In this way, when the container manufacturing line 10 and the filling line 20 are connected, it may be referred to as an in-line connection. The manufacturing system 100 of this example can manage the container manufacturing line 10 and the filling line 20 consistently by connecting the container manufacturing line 10 and the filling line 20 in-line. For example, the manufacturing system 100 can control the operations of the container manufacturing line 10 and the filling line 20 according to the line speed, maintenance period, and the like.

[0038] FIG. 1B shows an example of a more specific configuration of the manufacturing system 100. The container manufacturing line 10 includes a pre-printing process 11, a printing process 12, a post-printing process 13, and a first speed control unit 15. The filling line 20 includes a pre-filling process 21, a filling and sealing process 22, and a post-filling process 23. In this example, an example in which the container 200 is a metal can will be described, but it is not limited thereto.

[0039] The pre-printing process 11 includes a capping press process (CP), a body maker process (BM), a trimmer process (TR), and a heat set process (HS).

[0040] In the capping press process (CP), a circular material member is punched out from a sheet-shaped sheet metal unwound from a coil which is a preliminary material 210 and formed into a cup shape. In the body maker process (BM), the cup-shaped material member C1 is drawn and processed to thinly extend the can body portion, and further the can bottom portion is formed to form the can body C2. Note that in the trimmer process (TR), unnecessary portions at the upper end of the can body may be cut off. Thereafter, in the heat set process (HS), the container 200 may be heated.

[0041] The printing process 12 includes a printing process (PR) for printing a predetermined image on the container 200. The content printed in the printing process (PR) is not particularly limited. For example, in the printing process (PR), painting and printing are performed on the can body portion of the can body C2. In the printing process (PR), an image is printed on the container 200 at a predetermined printing speed. The printing speed in the printing process (PR) may be fixed or variable. The printing apparatus in the printing process (PR) may be a plate printing apparatus or a plate-less printing apparatus.

[0042] The post-printing process 13 includes a spray process (SP), an oven process (Oven), and a necking process (Ne). In the spray process (SP), the inner surface of the container 200 is painted. The oven process (Oven) is a process of baking the ink printed on the container 200 by heating or the like. The oven process (Oven) may be a method other than heating such as irradiating ultraviolet rays. In the necking process (Ne), a die is pressed against the upper portion of the can body, and the upper portion of the can body is processed to reduce the diameter. Note that when the inner surface of the can body is laminated, the spray process (SP) may be omitted.

[0043] The first speed control unit 15 controls the manufacturing line speed according to the filling line speed of the filling line 20. The first speed control unit 15 adjusts the manufacturing line speed so as to match the filling line speed. Matching the speeds does not necessarily mean making the line speeds the same. For example, matching the speeds may include feedback controlling the line speed so that the manufacturing line speed approaches the filling line speed.

[0044] The manufacturing line speed is the line speed of the container manufacturing line 10. For example, the manufacturing line speed is the number of containers 200 on which an image is printed in the printing process 12 per unit time. Also, the manufacturing line speed may be the number of containers 200 conveyed from the container manufacturing line 10 per unit time.

[0045] The filling line speed is the line speed of the filling line 20. For example, the filling line speed is the number of containers 200 in which a filling material is filled and sealed in the filling and sealing process 22 per unit time. Also, the filling line speed may be the number of containers 200 taken out from the filling line 20 per unit time.

[0046] Also, the first speed control unit 15 may control the manufacturing line speed to be greater than the filling line speed. The first speed control unit 15 may control so that the manufacturing line speed is greater than 10% of the filling line speed, or may control so that it is greater than 20% of the filling line speed. The first speed control unit 15 may determine the increase rate of the manufacturing line speed according to the filling line speed.

[0047] Also, the first speed control unit 15 may set a plurality of manufacturing line speeds in advance and select any one of the plurality of manufacturing line speeds according to the situation. For example, the first speed control unit 15 may set a first manufacturing line speed S1 corresponding to the filling line speed and a second manufacturing line speed S2 higher than the first manufacturing line speed S1, and switch between the first manufacturing line speed S1 and the second manufacturing line speed S2. The first speed control unit 15 may set three or more manufacturing line speeds in advance.

[0048] In one example, the first speed control unit 15 changes the manufacturing line speed of the container manufacturing line 10 according to the change amount of the number of containers 200 in a predetermined process of the filling line 20. The first speed control unit 15 may decrease the manufacturing line speed when the number of containers 200 increases, and increase the manufacturing line speed when the number of containers 200 decreases. The first speed control unit 15 adjusts the change amount of the manufacturing line speed so that the containers 200 conveyed to the filling line 20 are not insufficient.

[0049] The pre-filling process 21 is a process upstream of the filling and sealing process 22 in the line. The pre-filling process 21 includes a pre-filling inspection process (TST1) and a cleaning process (CR). In the pre-filling inspection process (TST1), the quality of the container 200 is inspected. For example, in the pre-filling inspection process (TST1), defects inside or outside the container 200 are inspected. The container 200 determined to be defective in the pre-filling inspection process (TST1) may be excluded from the line. In the cleaning process (CR), the container 200 is cleaned before filling the container 200 with the filling material. For example, in the cleaning process (CR), foreign matter and water droplets are blown off by spraying at least one of gas or liquid onto the container 200.

[0050] The filling and sealing process 22 includes a filling process (FL) for filling the container 200 with the filling material and a sealing process (Se). The filling material filled in the filling process (FL) may be, but is not limited to, beverages, foods, oils, detergents, cosmetics, etc. For example, in the filling process (FL), the container 200 is filled with a beverage at a predetermined filling speed. In the filling and sealing process 22, a maintenance period may be provided when changing the type of the filling material to be filled. In the sealing process (Se), the container 200 filled with the filling material is sealed. When the container 200 is a metal can, the container 200 is covered and sealed.

[0051] The post-filling process 23 is a process downstream of the filling and sealing process 22 in the line. The post-filling process 23 includes a sterilization process (St) and a post-filling inspection process (TST2). In the sterilization process (St), the container 200 is sterilized. In the post-filling inspection process (TST2), an inspection of the content volume and a sealing inspection of the container 200 are performed.

[0052] The first speed control unit 15 may change the manufacturing line speed according to the change amount of the number of containers 200 in the filling line 20. For example, the first speed control unit 15 increases the manufacturing line speed according to the decrease in the number of containers 200 conveyed in the filling line 20. Also, the first speed control unit 15 decreases the manufacturing line speed according to the increase in the number of containers 200 conveyed in the filling line 20. Thereby, the excess or deficiency of the containers 200 in the filling line 20 can be prevented. Furthermore, the manufacturing system 100 of this example can reduce the inventory of the containers 200 before filling by appropriately controlling the manufacturing line speed.

[0053] The pre-filling inspection process (TST1) is provided between the container manufacturing line 10 and the filling and sealing process 22 of the filling line 20. The pre-filling inspection process (TST1) of this example serves both as an inspection after the manufacture of the container 200 and an inspection before filling the container 200 with the filling material. That is, one pre-filling inspection process (TST1) is provided between the container manufacturing line 10 and the filling and sealing process 22. Thereby, the manufacturing system 100 of this example can reduce the number of times of the pre-filling inspection process (TST1) compared with the case where the container manufacturing line and the filling line are provided in separate factories and inspections are performed in each factory.

[0054] Also, in the pre-filling inspection process (TST1), the defective container 200 may be detected. For example, the filling line 20 may be provided with a sorting device after the pre-filling inspection process (TST1) to exclude the container 200 determined to be defective from the line.

[0055] FIG. 1C shows an example of the configuration of the manufacturing system 100. The manufacturing system 100 in this example is different from the case of FIG. 1B in that the filling line 20 is provided with the second speed control unit 25. In this example, the points different from the embodiment of FIG. 1B will be particularly described. The container manufacturing line 10 may not be provided with the first speed control unit 15.

[0056] The second speed control unit 25 controls the filling line speed of the filling line 20. The second speed control unit 25 may control the filling line speed according to the manufacturing line speed of the container manufacturing line 10. For example, the second speed control unit 25 adjusts the filling line speed so as to match the manufacturing line speed of the container manufacturing line 10. The second speed control unit 25 may control so that the filling line speed is slower than the manufacturing line speed.

[0057] In addition, the second speed control unit 25 may control the filling line speed according to the number of containers 200 conveyed to the filling line 20. For example, the second speed control unit 25 increases the filling line speed when the number of containers 200 conveyed to the filling line 20 increases. On the other hand, the second speed control unit 25 decreases the filling line speed when the number of containers 200 conveyed to the filling line 20 decreases. That is, controlling the filling line speed according to the number of containers 200 may include controlling the filling line speed according to the change rate of the containers 200 rather than the number of containers 200.

[0058] FIG. 1D shows an example of the configuration of the manufacturing system 100. The manufacturing system 100 in this example includes both the first speed control unit 15 and the second speed control unit 25. In this example, the points different from the embodiments of FIGS. 1B and 1C will be particularly described. Note that the first speed control unit 15 and the second speed control unit 25 may each execute the control described in the embodiments of FIGS. 1B and 1C.

[0059] Manufacturing system 100 may maintain a constant overall line speed of container manufacturing line 10 and filling line 20 by changing the line speed of at least one of container manufacturing line 10 or filling line 20. For example, when the filling line speed is lower than the manufacturing line speed, the first speed control unit 15 reduces the manufacturing line speed to maintain a constant overall line speed. When the filling line speed is higher than the manufacturing line speed, the second speed control unit 25 may reduce the filling line speed to maintain a constant overall line speed.

[0060] Manufacturing system 100 may control the manufacturing line speed according to the number of containers 200 conveyed to filling line 20. For example, manufacturing system 100 increases the manufacturing line speed when the number of containers 200 conveyed is less than a predetermined number. In one example, the first speed control unit 15 increases the manufacturing line speed by 10% when the number of containers 200 is below an arbitrary threshold, and decreases the manufacturing line speed by 10% when the number of containers 200 exceeds an arbitrary threshold. Thereby, manufacturing system 100 can stably convey containers 200 to filling line 20. The rate of increasing or decreasing the line speed is not limited to this.

[0061] The timing for measuring the number of containers 200 may be any process prior to the filling and sealing process 22. The number of containers 200 may be measured by a sensor, or the rate of change of the number of containers 200 may be measured. That is, manufacturing system 100 only needs to determine whether the number of containers 200 conveyed to filling line 20 is sufficient, and it is not necessarily required to measure the number of containers 200.

[0062] FIG. 2A shows an example of a connection method between container manufacturing line 10 and filling line 20. The manufacturing system 100 of this example includes a line connection portion 110 between container manufacturing line 10 and filling line 20.

[0063] The line connection part 110 connects the container manufacturing line 10 and the filling line 20, and conveys the container 200 manufactured on the container manufacturing line 10 to the filling line 20. That is, in the line connection part 110, the container 200 is conveyed to the filling line 20 without taking out the container 200 manufactured by the container manufacturing line 10 from the line. Thus, the line connection part 110 of this example inlines the container manufacturing line 10 and the filling line 20.

[0064] FIG. 2B shows an example of a connection method between the container manufacturing line 10 and the filling line 20. The line connection part 110 of this example is different from the embodiment of FIG. 2A in that it includes an in-line accumulation part 112.

[0065] The in-line accumulation part 112 is provided between the container manufacturing line 10 and the filling line 20 and accumulates the containers 200. The in-line accumulation part 112 of this example is provided in a process before the filling line 20, and accumulates the containers 200 conveyed at a speed higher than the filling line speed. Thereby, the in-line accumulation part 112 can stably supply the containers 200 to the filling line 20 even when the line speeds of the container manufacturing line 10 and the filling line 20 are different. Also, if the containers 200 are stably supplied to the filling line 20, it is possible to prevent the filler from being wasted due to the shortage of the containers 200.

[0066] Also, by providing the in-line accumulation part 112, the filling line 20 can continue to operate even when the manufacturing line speed decreases. Therefore, the manufacturing system 100 of this example can connect the container manufacturing line 10 and the filling line 20 and maintain the overall production efficiency even when the line speed changes.

[0067] Note that the position where the in-line accumulation unit 112 is provided does not have to be between the container manufacturing line 10 and the filling line 20. The in-line accumulation unit 112 may be provided during any of the processes of the container manufacturing line 10 or the filling line 20. For example, the in-line accumulation unit 112 may be provided in the container manufacturing line 10 after the printing process 12. Also, the in-line accumulation unit 112 may be provided in the filling line 20 before the filling and sealing process 22. A plurality of in-line accumulation units 112 may be provided in the manufacturing system 100. The in-line accumulation unit 112 may be provided at an arbitrary position in the manufacturing system 100 described in other embodiments.

[0068] FIG. 2C shows an example of a method of connecting the container manufacturing line 10 and the filling line 20. The manufacturing system 100 of this example includes a sorting device 130 between the container manufacturing line 10 and the filling line 20. Also, the manufacturing system 100 includes a line connection unit 110 and an offline accumulation unit 120 between the container manufacturing line 10 and the filling line 20.

[0069] The sorting device 130 sorts the containers 200 manufactured by the container manufacturing line 10 to the line connection unit 110 or the offline accumulation unit 120. The sorting device 130 may determine the sorting destination according to the manufacturing line speed and the filling line speed. Also, the sorting device 130 may switch the sorting destination according to the inventory status of the containers 200 in the manufacturing system 100.

[0070] For example, when the manufacturing line speed of the container manufacturing line 10 is faster than the filling line speed of the filling line 20 and the number of containers in the filling line 20 exceeds a predetermined ratio to the capacity of the filling line 20, the manufacturing system 100 may sort it to the first accumulation process. The predetermined ratio to the capacity of the filling line 20 may be 100%, 95%, or 90%. The first accumulation process in this example is the offline accumulation unit 120.

[0071] The sorting method by the sorting device 130 is any one of a partition plate method, a turret method, a slider method, a roller method, a pick-up method, a vacuum method, or an air method. The partition plate method moves a partition plate that guides the container 200 to change the sorting destination line. The turret method uses a turret that rotates to convey the container 200 for sorting.

[0072] In the slider method, the container 200 is placed on a slider conveyed by a conveyor for sorting. In the roller method, the sorting is achieved by changing the rotation direction of rollers embedded in the surface of the conveyor. In the pick-up method, the container 200 is picked up by a robot to change the sorting destination.

[0073] The vacuum method is a method that realizes sorting using vacuum means in the turret method, the slider method, the pick-up method, etc. The air method is a method of blowing arbitrary air onto the container 200 to change the line of the container 200 or drop the container 200 from the line.

[0074] The offline accumulation unit 120 is provided between the container manufacturing line 10 and the filling line 20 to accumulate the containers 200. The offline accumulation unit 120 in this example is provided in a process before the filling line 20, so as to accumulate the containers 200 conveyed at a speed higher than the filling line speed offline. Thereby, the offline accumulation unit 120 can supply the container 200 to the filling line 20 at an appropriate timing, such as after the stop time of the filling line 20 has elapsed.

[0075] The offline storage unit 120 stores the containers 200 manufactured by the container manufacturing line 10 offline. Since the offline storage unit 120 is offline, it is not connected to the container manufacturing line 10 and the filling line 20. For example, the offline storage unit 120 is a palletizer for stacking the containers 200 on a pallet. The offline storage unit 120 may provide the stored containers 200 to the filling line 20. In one example, the offline storage unit 120 provides the containers 200 to the filling line 20 when the container manufacturing line 10 stops.

[0076] Note that the offline storage unit 120 may have a larger storage capacity than the in-line storage unit 112. Since the offline storage unit 120 is offline, it is easier to increase or decrease the storage capacity than the in-line storage unit 112. When the offline storage unit 120 is a palletizer for storing the containers 200, the number of palletizers may be increased to increase the storage capacity of the offline storage unit 120. When the storage capacity of the in-line storage unit 112 is insufficient, the use of the offline storage unit 120 can cope with a larger line speed difference. Also, by using the offline storage unit 120, even when the stop time of the filling line 20 is long, the timing of transporting the containers 200 can be easily adjusted.

[0077] FIG. 2D shows an example of a connection method between the container manufacturing line 10 and the filling line 20. The sorting device 130 in this example sorts the containers 200 to the in-line storage unit 112 or the offline storage unit 120. The manufacturing system 100 in this example is different from the embodiment of FIG. 2C in that the in-line storage unit 112 is provided in the line connection unit 110.

[0078] The sorting device 130 sorts the containers 200 manufactured by the container manufacturing line 10 to the in-line storage unit 112 or the offline storage unit 120. For example, the sorting device 130 changes the sorting destination to the offline storage unit 120 when the storage capacity of the in-line storage unit 112 becomes insufficient while sorting the containers 200 to the in-line storage unit 112.

[0079] Further, the sorting device 130 may store the containers in the second storage process when the production line speed of the container production line 10 is faster than the filling line speed of the filling line 20, and the number of containers in the filling line 20 exceeds a predetermined ratio with respect to the capacity of the filling line 20 and a predetermined ratio with respect to the storage capacity of the first storage process. The predetermined ratio with respect to the storage capacity of the first storage process may be 100%, 95%, or 90%. In this example, the first storage process is the in-line storage unit 112, and the second storage process is the off-line storage unit 120.

[0080] Here, in each process of the manufacturing system 100, a stop time may occur due to maintenance of the device or the like. For example, in the container production line 10, the printing process 12 may stop due to plate change of the printing device. In the filling line 20, when the filling material is changed, the filling and sealing process 22 may stop for cleaning the device. The periods or frequencies of line stops are different between the container production line 10 and the filling line 20. Further, there may be variations in the plate change time of the container production line 10.

[0081] The manufacturing system 100 of this example determines the sorting destination of the containers 200 by the sorting device 130 according to the line stop times of the container production line 10 and the filling line 20. Further, the manufacturing system 100 may change the sorting destination by the sorting device 130 according to the line stop time of the container production line 10 or the filling line 20. Thereby, the manufacturing system 100 can realize a combination of lines with different line speeds and maintenance periods.

[0082] For example, when the container manufacturing line 10 is stopped, the containers 200 accumulated in the in-line accumulation unit 112 or the off-line accumulation unit 120 can be conveyed to the filling line 20 to maintain a constant filling line speed. On the other hand, when the filling line 20 is stopped, the containers 200 are distributed to the in-line accumulation unit 112 or the off-line accumulation unit 120 to stop the conveyance of the containers 200 to the filling line 20. The distribution device 130 may distribute to the in-line accumulation unit 112 when the stop time of the filling line 20 is shorter than a predetermined time, and distribute to the off-line accumulation unit 120 when the stop time of the filling line 20 is longer than the predetermined time.

[0083] Note that the distribution method by the distribution device 130 is not limited to this example. The distribution device 130 may distribute the containers 200 to the line connection part 110 without the in-line accumulation unit 112 and the line connection part 110 with the in-line accumulation unit 112. Further, the distribution device 130 may distribute to any one of the line connection part 110 without the in-line accumulation unit 112, the line connection part 110 with the in-line accumulation unit 112, and the off-line accumulation unit 120.

[0084] FIG. 2E shows an example of the manufacturing system 100 in cooperation with the factory 300. The factory 300 is a factory different from the factory of the manufacturing system 100.

[0085] The manufacturing system 100 may ship the containers 200 accumulated in the off-line accumulation unit 120 to the factory 300. Further, the filling line 20 may fill the filling material using the containers 200 of the off-line accumulation unit 120 received from the factory 300. Note that the off-line accumulation unit 120 may accumulate the containers 200 manufactured by a container manufacturing line different from the container manufacturing line 10 when the manufacturing system 100 includes a plurality of container manufacturing lines 10.

[0086] The sorting device 130 may sort a part of the containers 200 to the in-line storage unit 112 and the remaining containers 200 to the off-line storage unit 120. Thereby, the manufacturing system 100 can convey a part of the containers 200 to the filling line 20 and ship the remaining containers 200 to the factory 300.

[0087] As shown in FIGS. 2A to 2E, by appropriately selecting the connection method between the container manufacturing line 10 and the filling line 20, it becomes easier to control the filling line speed constantly. Also, in the manufacturing system 100, it becomes easier to realize appropriate inventory management and avoid waste of materials.

[0088] The manufacturing system 100 may change the connection method between the container manufacturing line 10 and the filling line 20 according to the manufacturing line speed and the filling line speed. For example, the manufacturing system 100 changes the sorting destination according to the degree of the line speed difference. The line speed difference refers to the line speed difference between the manufacturing line speed and the filling line speed.

[0089] Also, the manufacturing system 100 may change the sorting destination according to the line speed ratio. The line speed ratio is the ratio of the filling line speed of the filling line 20 to the manufacturing line speed of the container manufacturing line 10. That is, the line speed ratio = filling line speed / manufacturing line speed holds. The line speed difference becomes larger as the line speed ratio deviates from 1. The line speed difference becomes smaller as the line speed ratio approaches 1.

[0090] When the line speed difference is relatively small, the manufacturing system 100 may convey the containers 200 to the filling line 20 via the line connection part 110. In one example, when the line speed difference is relatively small, it means that the line speed difference is small to the extent that the accumulation process is unnecessary. For example, it is the case where the line speed ratio is 0.25 or more and 1.80 or less. In this case, the manufacturing system 100 may connect the container manufacturing line 10 and the filling line 20 with the line connection part 110 as shown in FIG. 2A. Also, in the embodiment of FIG. 2C, the manufacturing system 100 may sort the containers 200 to the line connection part 110 by the sorting device 130.

[0091] When the line speed difference is moderate, the manufacturing system 100 may convey the containers 200 to the filling line 20 via the in-line accumulation unit 112 or the off-line accumulation unit 120. In one example, when the line speed difference is moderate, it means that an accumulation process is necessary but the line speed difference is not large enough to require the off-line accumulation unit 120. In this case, the manufacturing system 100 may include an in-line accumulation unit 112 between the container manufacturing line 10 and the filling line 20 as shown in FIG. 2B. Also, in the embodiment of FIG. 2C, the manufacturing system 100 may distribute the containers 200 to the off-line accumulation unit 120 by the sorting device 130. In the embodiments of FIGS. 2D and 2E, the manufacturing system 100 may distribute the containers 200 to the in-line accumulation unit 112 or the off-line accumulation unit 120 by the sorting device 130.

[0092] When the line speed difference is relatively large, the manufacturing system 100 may convey the containers 200 to the filling line 20 via the off-line accumulation unit 120. In one example, when the line speed difference is relatively large, it means that the line speed difference is large enough to require the off-line accumulation unit 120. In this case, in the embodiments of FIGS. 2C, 2D and 2E, the manufacturing system 100 may distribute the containers 200 to the off-line accumulation unit 120 by the sorting device 130.

[0093] In addition, the manufacturing system 100 may attach a label with any printed image to the container 200. The type of label may be any label such as a shrink label, a stretch label, a roll label or a sticker label. The label may be attached at any of the container manufacturing line 10, the filling line 20 or the line connection part 110. When using a label, the printing process 12 may be omitted.

[0094] FIG. 3 shows an example of the configuration of the manufacturing system 100 including a preliminary material manufacturing line 30. The preliminary material manufacturing line 30 in this example may be appropriately provided in the manufacturing system 100 according to other embodiments.

[0095] The preliminary material manufacturing line 30 is provided upstream of the container manufacturing line 10 and manufactures the preliminary material 210. The preliminary material manufacturing line 30 manufactures the preliminary material 210 at a predetermined preliminary material manufacturing line speed. The preliminary material manufacturing line 30 is connected to the container manufacturing line 10 and supplies the manufactured preliminary material 210 to the container manufacturing line 10. That is, the preliminary material manufacturing line 30 of this example is in-line connected to the container manufacturing line 10.

[0096] The preliminary material manufacturing line 30 may be a laminating line for laminating the preliminary material 210 by a film lamination method or an extrusion lamination method or the like. The film lamination method is a method of laminating by thermally bonding or bonding a preformed film to a metal base material with an adhesive or the like. The extrusion lamination method is a method of laminating by bonding a molten thin film of a thermoplastic resin extruded from a T-die to a metal base material.

[0097] The third speed control unit 35 controls the preliminary material manufacturing line speed according to the manufacturing line speed and the filling line speed. For example, the third speed control unit 35 controls the preliminary material manufacturing line speed to match the manufacturing line speed and the filling line speed. Also, the third speed control unit 35 may control so that the preliminary material manufacturing line speed is greater than the manufacturing line speed.

[0098] Note that the manufacturing system 100 may further include a first speed control unit 15 and a second speed control unit 25. The manufacturing system 100 may control so that the line speed on the upstream side increases. For example, the third speed control unit 35 controls so that the preliminary material manufacturing line speed is greater than the manufacturing line speed and the filling line speed. Also, the first speed control unit 15 may control so that the manufacturing line speed is greater than the filling line speed. By increasing the line speed on the upstream side and accumulating the containers 200, it is possible to avoid a shortage of the containers 200.

[0099] For example, the manufacturing system 100 may adjust each line speed so that the line speed satisfies any one of (1) to (3). (1) Preparatory material manufacturing line speed = manufacturing line speed = filling line speed (2) Preparatory material manufacturing line speed = manufacturing line speed > filling line speed (3) Preparatory material manufacturing line speed > manufacturing line speed > filling line speed

[0100] The manufacturing system 100 of this example can further reduce waste in inventory by connecting the preparatory material manufacturing line 30, the container manufacturing line 10, and the filling line 20 in-line. The manufacturing system 100 of this example can achieve stable manufacturing while reducing the inventory of both the container 200 and the preparatory material 210. Note that an accumulation process for accumulating the preparatory material 210 may be provided between the preparatory material manufacturing line 30 and the container manufacturing line 10. The accumulation process between the preparatory material manufacturing line 30 and the container manufacturing line 10 may be in-line or offline.

[0101] FIG. 4A shows an example of the configuration of the container manufacturing line 10 including the partition portion 150. The container manufacturing line 10 of this example includes the partition portion 150.

[0102] The partition portion 150 covers the periphery of a predetermined process. The partition portion 150 controls the environment of the partitioned space by partitioning the space. The partition portion 150 is used to control at least one of the room temperature, humidity, air pressure (positive pressure or negative pressure), odor, or cleanliness of the space. For example, the partition portion 150 is a curtain or a wall. The manufacturing system 100 may include a clean room configured by the partition portion 150.

[0103] The partition portion 150 may be provided in at least a part of the processes of the container manufacturing line 10. The partition portion 150 of this example is provided in the printing process 12. The partition portion 150 surrounds the periphery of the devices used in the printing process 12. Thereby, the partition portion 150 prevents the outflow of odors such as ink from the printing process 12 to the filling line 20. Note that the manufacturing system 100 may prevent the outflow of odors to other processes by controlling the air flow direction of the air conditioning in the factory.

[0104] The partition part 150 may achieve a cleanliness class different from other processes. The partition part 150 may be the wall of the clean room. For example, the partition part 150 makes the cleanliness class of the filling line 20 higher than that of the container manufacturing line 10.

[0105] The manufacturing system 100 of this example can control the environment and stabilize the quality by partitioning predetermined processes with the partition part 150. Also, the manufacturing system 100 of this example can suppress the influence from other processes and improve the hygiene by partitioning predetermined processes with the partition part 150. The partition part 150 may be provided across a plurality of processes.

[0106] FIG. 4B shows an example of the configuration of the manufacturing system 100 including the partition part 150. The manufacturing system 100 of this example includes the partition part 150 in the filling line 20.

[0107] The partition part 150 is provided in at least a part of the processes of the filling line 20. The partition part 150 of this example is provided in the filling and sealing process 22. Thereby, the partition part 150 prevents foreign matter from entering the filling and sealing process 22. Thereby, even when the filling line 20 is in-line connected to the container manufacturing line 10 and the preliminary material manufacturing line 30, the mutual influence can be reduced. Note that the partition part 150 may be provided in both any process of the container manufacturing line 10 and any process of the filling line 20.

[0108] FIG. 4C shows an example of the configuration of a manufacturing system 100 including a partition portion 150. The manufacturing system 100 in this example includes the partition portion 150 in a semifinished product manufacturing line 30. In this example, the cleanliness class of the semifinished product manufacturing line 30 is higher than that of the container manufacturing line 10. That is, manufacturing processes such as laminating on a coil of a metal can or a preform of a PET bottle are processed in an environment with a higher cleanliness class than a printing process on the container 200 or the like. Note that the partition portion 150 may be provided in other processes among the container manufacturing line 10 and the filling line 20. Thereby, even when the semifinished product manufacturing line 30 and the container manufacturing line 10 are in-line connected, the influence of the container manufacturing line 10 and the filling line 20 on the semifinished product manufacturing line 30 can be reduced.

[0109] FIG. 5 shows a modification of the container manufacturing line 10. The container 200 in this example is a metal can provided with a resin coating on both the inner and outer surfaces. Since the resin coating of the container 200 functions as a lubricant, the washing process (WM) after the forming process can be omitted.

[0110] The container manufacturing line 10 in this example has an oven process (Oven) after the printing process (PR) of the printing process 12, while not having a spray process (SP) and an oven process (Oven) in the post-printing process 13. Further, since the container 200 is manufactured into a can without using a lubricant in the container manufacturing line 10 in this example, a washing process (WM) after forming may not be provided.

[0111] The manufacturing system 100 in this example has a first speed control unit 15 in the container manufacturing line 10, and controls the manufacturing line speed by adjusting the speed of the printing process (PR) according to the filling line speed of the filling line 20. Note that the container manufacturing line 10 in this example may be appropriately combined and used in the manufacturing system 100 of other embodiments. That is, the manufacturing system 100 may have a second speed control unit 25, or may have both the first speed control unit 15 and the second speed control unit 25.

[0112] FIG. 6 shows a modified example of the container manufacturing line 10 for DI cans. The container 200 in this example is a DI can. The DI can is formed into a bottomed cylindrical shape by subjecting a cup-shaped material member C1 to a DI process (i.e., a drawing process). The pre-printing process 11 in this example has a cleaning process (WM) after a trimmer process (TR). Note that the container manufacturing line 10 in this example may be appropriately combined and used with the manufacturing system 100 of other embodiments.

[0113] FIG. 7 shows a modified example of the container manufacturing line 10 for three-piece cans. The container 200 in this example is a three-piece can in which members are joined by welding. The container manufacturing line 10 has a slitter process (SL), a welding process (W), a spray process (SP), an oven process, a necking process (Ne), a seaming process (SM), and an empty can inspection process (TST).

[0114] In the slitter process (SL), a preliminary material 210 is divided into the size of one can of the container 200 to form a sheet-like sheet metal. The sheet-like preliminary material 210 may have an arbitrary image printed thereon before being made into a can. In the welding process (W), both ends of the sheet-like preliminary material 210 are welded and joined to form a cylindrical container 200. In the spray process (SP), paint is sprayed on the inner and outer surfaces of the welded portion of the container 200 for protection. In the seaming process (SM), a bottom lid is wound and fastened to one opening of the cylindrical container 200. In the empty can inspection process (TST), a leak inspection of the empty can of the container 200 is performed.

[0115] The first speed control unit 15 may control the manufacturing line speed by adjusting the speed of the welding process (W) according to the filling line speed of the filling line 20. Further, the first speed control unit 15 may control the manufacturing line speed by adjusting the speeds of processes other than the welding process (W). Note that the container manufacturing line 10 in this example may be appropriately combined and used with the manufacturing system 100 of other embodiments.

[0116] FIG. 8 shows a modified example of the manufacturing system 100 for the label container. The container 200 in this example is a label container with a label printed with an arbitrary image attached to the container. The container 200 may be a label can with a label attached to a metal can.

[0117] The container manufacturing line 10 has a pre-labeling process 16, a label attaching process 17, and a post-labeling process 18. The pre-labeling process 16 and the post-labeling process 18 may include processes similar to the pre-printing process 11 and the post-printing process 13 in other embodiments. In the case of a label container, the container manufacturing line 10 may not have a printing process 12, but may further have a printing process 12 in addition to the label attaching process 17.

[0118] The label attaching process 17 has a labeling process (L) for attaching a label printed with an arbitrary image to the container 200. The type of label may be any label such as a shrink label, a stretch label, a roll label, or a sticker label. The label attaching process 17 is provided between the pre-labeling process 16 and the post-labeling process 18, but may also be provided after the necking process (Ne) of the post-labeling process 18.

[0119] Also, the label attaching process 17 may be provided on the filling line 20. The label attaching process 17 may be provided before the pre-filling inspection process (TST1) of the pre-filling process 21, may be provided in any process between the sealing process (Se) and the post-filling inspection process (TST2), or may be provided after the post-filling inspection process (TST2).

[0120] The first speed control unit 15 may control the manufacturing line speed by adjusting the speed of the label attaching process 17 according to the filling line speed of the filling line 20. Also, the first speed control unit 15 may control the manufacturing line speed by adjusting the speeds of processes other than the label attaching process 17. Note that the container manufacturing line 10 in this example may be used in appropriate combination with the manufacturing system 100 in other embodiments. The manufacturing system 100 may be used in combination with the second speed control unit 25, or may be used in combination with the first speed control unit 15 and the second speed control unit 25.

[0121] Figure 9 shows a modified example of the manufacturing system 100. The manufacturing system 100 in this example includes an identification information adding step (ID) in the pre-printing step 11. In the identification information adding step (ID), individual identification information ID for identifying the individual containers 200 is added. The individual identification information ID may be used for identifying the individuals of the containers 200 in each step of the manufacturing system 100. The filling line 20 in this example identifies the containers 200 using the individual identification information ID given by the container manufacturing line 10. As a result, it becomes unnecessary to add the individual identification information ID in the filling line 20.

[0122] The identification information adding step (ID) is provided before the capping press step (CP), but is not limited to this position. For example, the identification information adding step (ID) may be after the capping press step (CP), the body maker step (BM), or the trimmer step (TR). In the identification information adding step (ID) of this example, the individual identification information ID is added to the coil before punching, but the individual identification information ID may be added to the container 200 after punching.

[0123] The manufacturing system 100 in this example can control the manufacturing line speed by sharing the individual identification information ID between the container manufacturing line 10 and the filling line 20. By using the common individual identification information ID, the management of the individuals of the containers 200 becomes easy for the entire manufacturing system 100, and it becomes easier to control the line speed.

[0124] As described above, the present invention has been described using the embodiments, but the technical scope of the present invention is not limited to the scope described in the above embodiments. It is obvious to those skilled in the art that various changes or improvements can be made to the above embodiments. It is clear from the description of the claims that forms with such changes or improvements can also be included in the technical scope of the present invention.

[0125] In the claims, the specification, and the drawings, the execution order of each process such as operations, procedures, steps, and stages in the apparatus, system, program, and method shown is not explicitly indicated as "earlier" or "preceding" etc. in particular. It should be noted that it can be realized in any order unless the output of the previous process is used in the subsequent process. Regarding the operation flow in the claims, the specification, and the drawings, even if it is described using "first," "next," etc. for convenience, it does not mean that it is essential to be implemented in this order.

Explanation of Signs

[0126] 10... Container manufacturing line, 11... Pre-printing process, 12... Printing process, 13... Post-printing process, 15... First speed control unit, 16... Pre-label process, 17... Label attachment process, 18... Post-label process, 20... Filling line, 21... Pre-filling process, 22... Filling and sealing process, 23... Post-filling process, 25... Second speed control unit, 30... Pre-material manufacturing line, 35... Third speed control unit, 100... Manufacturing system, 110... Line connection part, 112... In-line accumulation part, 120... Off-line accumulation part, 130... Sorting device, 150... Partition part, 200... Container, 210... Pre-material, 300... Factory

Claims

1. A container manufacturing line for manufacturing containers, a filling line for filling the containers with a filling material, a first accumulation step of accumulating the containers between the container manufacturing line and the filling and sealing step of the filling line, a second accumulation step of accumulating the containers between the container manufacturing line and the filling and sealing step, the second accumulation step having a larger accumulation capacity than the first accumulation step, comprising: the container manufacturing line is connected to the filling line, and the containers manufactured on the container manufacturing line are supplied to the filling line, the manufacturing line speed of the container manufacturing line is faster than the filling line speed of the filling line, and when the number of containers in the filling line exceeds a predetermined ratio to the capacity of the filling line and a predetermined ratio to the accumulation capacity of the first accumulation step, they are accumulated in the second accumulation step, the first accumulation step is an inline step connected to the container manufacturing line and the filling line, the second accumulation step is an offline step not connected to the container manufacturing line and the filling line manufacturing system.

2. A container manufacturing line for manufacturing containers, a filling line for filling the containers with a filling material, a first accumulation step of accumulating the containers between the container manufacturing line and the filling and sealing step of the filling line, a second accumulation step of accumulating the containers between the container manufacturing line and the filling and sealing step, the second accumulation step having a larger accumulation capacity than the first accumulation step, comprising: the container manufacturing line is connected to the filling line, and the containers manufactured on the container manufacturing line are supplied to the filling line, the manufacturing line speed of the container manufacturing line is faster than the filling line speed of the filling line, and when the number of containers in the filling line exceeds a predetermined ratio to the capacity of the filling line and a predetermined ratio to the accumulation capacity of the first accumulation step, they are accumulated in the second accumulation step, the manufacturing line speed of the container manufacturing line is faster than the filling line speed of the filling line, and when the number of containers in the filling line exceeds a predetermined ratio to the capacity of the filling line, they are distributed to the first accumulation step manufacturing system.

3. The container manufacturing line has a first speed control unit for controlling the manufacturing line speed according to the filling line speed of the filling line, The filling line has a second speed control unit for controlling the filling line speed according to the manufacturing line speed of the container manufacturing line. The manufacturing system according to claim 1 or 2.

4. The first speed control unit changes the manufacturing line speed of the container manufacturing line according to the change amount of the number of the containers in a predetermined process of the filling line. The manufacturing system according to claim 3.

5. The first speed control unit adjusts the manufacturing line speed so as to match the filling line speed. The manufacturing system according to claim 3 or 4.

6. The first speed control unit a first manufacturing line speed corresponding to the filling line speed, and a second manufacturing line speed higher than the first manufacturing line speed and switches between them. The manufacturing system according to any one of claims 3 to 5.

7. The second speed control unit adjusts the filling line speed so as to match the manufacturing line speed of the container manufacturing line. The manufacturing system according to any one of claims 3 to 6.

8. By changing at least one of the line speeds of the container manufacturing line or the filling line, the overall line speeds of the container manufacturing line and the filling line are kept constant. The manufacturing system according to any one of claims 3 to 7.

9. When the ratio of the filling line speed of the filling line to the manufacturing line speed of the container manufacturing line is 0.25 or more and 1.80 or less, it is distributed to the filling line. The manufacturing system according to any one of claims 1 to 8.

10. Determine the distribution destination of the containers from the container manufacturing line according to the line stop times of the container manufacturing line and the filling line. The manufacturing system according to any one of claims 1 to 9.

11. It is provided with a partition part that covers the periphery of a predetermined process. The manufacturing system according to any one of claims 1 to 10.

12. The partition part realizes a cleanliness class different from other processes. The manufacturing system according to claim 11.

13. The partition part is provided in at least a part of the processes of the container manufacturing line. The manufacturing system according to claim 11 or 12.

14. The partition part is provided in at least a part of the processes of the filling line. The manufacturing system according to any one of claims 11 to 13.

15. An inspection process is provided between the container manufacturing line and the filling and sealing process of the filling line. The manufacturing system according to any one of claims 1 to 14.

16. A preliminary material manufacturing line provided in the front stage of the container manufacturing line for manufacturing a preliminary material for manufacturing the container is provided. The preliminary material manufacturing line is connected to the container manufacturing line, and the preliminary material manufactured by the preliminary material manufacturing line is supplied to the container manufacturing line. The manufacturing system according to any one of claims 1 to 15.

17. The preliminary material manufacturing line includes a third speed control unit for controlling the preliminary material manufacturing line speed according to the manufacturing line speed of the container manufacturing line and the filling line speed of the filling line. The manufacturing system according to claim 16.

18. The cleanliness class of the preliminary material manufacturing line is higher than the cleanliness class of the container manufacturing line. The manufacturing system according to claim 16 or 17.

19. The container is a metal can. The manufacturing system according to any one of claims 1 to 18.

20. The container manufacturing line or the filling line includes a label attaching process for attaching a label printed on the container. The manufacturing system according to any one of claims 1 to 19.

21. The container manufacturing line includes an identification information providing process for providing individual identification information for identifying an individual of the container, The filling line identifies the container using the individual identification information. The manufacturing system according to any one of claims 1 to 20.

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