Bottling Line Buffer Control for Continuous Container Flow

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Solution Overview

Problem

Existing bottling plants face inefficiencies and production stoppages due to the need to halt production when storing containers, leading to increased processing times and costs, as they lack flexibility and synchronization between machines upstream and downstream of the storage apparatus.

Innovation Solution

A bottling plant with a logic control unit managing multiple transport systems and operative speeds to enable container storage without stopping machines upstream or downstream, utilizing a storage apparatus with separate transport systems and modes to adjust production based on machine needs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If a common transport system is used to connect all machines in the bottling line, then the containers can be transported between machines, but a problem in one machine causes a simultaneous stop of the entire line

Engineering Contradiction:

Improvecontainer transport between machinesVSAvoidproduction line continuity

Core Design Contradiction:

Ease of operationVSProductivity

Solution Approach 1:

The transport system is segmented into a first transport system connecting upstream machines to the storage apparatus, and a second transport system connecting downstream machines to the storage apparatus. This segmentation isolates transport flows so that problems in one section do not propagate to the entire line, allowing independent operation of upstream and downstream sections.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The storage apparatus acts as an intermediary buffer between upstream and downstream machines. It temporarily stores containers and decouples the upstream and downstream transport systems, enabling one section to continue operating even when the other section experiences problems or requires maintenance.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If storage apparatus is added to the bottling line, then container storage capability is improved, but the system complexity increases

Engineering Contradiction:

Improveproduction continuityVSAvoidtransport system structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The storage apparatus is designed to perform multiple functions: it stores containers, buffers production fluctuations, and enables independent operation of upstream and downstream sections. This multi-functionality justifies the added complexity by providing comprehensive solutions to multiple production challenges simultaneously.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Ease of repair

If machines are stopped for maintenance or size changes, then proper maintenance or reconfiguration can be performed, but production productivity decreases

Engineering Contradiction:

Improvemachine maintenance accessVSAvoidproduction output

Core Design Contradiction:

Ease of repairVSProductivity

Solution Approach 1:

The storage apparatus accumulates containers in advance during normal operation. When maintenance or reconfiguration is needed, this pre-stored inventory allows downstream machines to continue operating without interruption, enabling maintenance activities to be performed without production loss.

Inventive Principle:

Principle #10Preliminary action

4Productivity

If high speed transport is used to maintain productivity, then production output is improved, but the risk of container damage increases

Engineering Contradiction:

Improvebottling speedVSAvoidcontainer damage risk

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The transport system is divided into separate sections with independent speed control. Each transport system can be optimized for its specific function: upstream transport can operate at higher speeds for productivity, while downstream transport can use lower speeds to reduce damage risk, eliminating the need for uniform high-speed operation across the entire line.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS12486155B2Plant for bottling containers with liquids and method for operating said plant

Publication Date: 2025.12.02 GRUPPO BERTOLASO

AI summary

Bottling plant comprising a first transport system which moves containers through different machines, and a storage apparatus, which comprises a storage unit, a second transport system which extracts the containers from the first transport system to feed the storage unit, and a third transport system which picks up the containers in the storage unit to feed the first transport system. The first transport system comprises an upstream conveyor actuated at a first operative speed, and a downstream conveyor actuated at a second operative speed. The plant further comprises a control unit programmed with: a by-pass mode, in which it commands the conveyors with equivalent operative speeds, a storage mode, in which it commands the conveyors with the first operative speed greater than the second operative speed, and a recovery mode, in which it commands the conveyors with the first operative speed lower than the second operative speed.