Segmented Buffer Conveyor for Thermoformed Bottle Preform Storage
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Solution Overview
Problem
Existing buffer stock devices in combined blowing-filling manufacturing lines for thermoformable plastic bottles are bulky and expensive, leading to inefficiencies when the filling line stops unexpectedly, causing unusable bottle preforms and potential scrap.
Innovation Solution
A compact buffer conveyor system with a first section for normal operation and a second section for storage during unplanned stoppages, sized to accommodate excess bottles, allowing continuous operation of the blowing equipment and preventing scrap by storing preforms until the filling line restarts, with a sizing condition of N22 > N8 + N1 - N4 - 1, where N8 and N1 represent the heating tunnel and blow molding equipment capacities, and N4 is the upstream handling device slots.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional buffer stock device is used between blowing equipment and filling line, then the filling line stoppage can be tolerated, but the device becomes bulky and expensive
Solution Approach 1:
The buffer conveyor is segmented into two functional sections: a first section (T21) for normal transfer operations and a second section (T22) for buffer storage during stoppages. This segmentation allows the same physical structure to serve dual purposes, eliminating the need for a separate bulky buffer device while maintaining reliability during filling line stoppages.
2Productivity
If the filling line stops unexpectedly, then bottles in progress must be discarded, but continuous operation is lost
Solution Approach 1:
The buffer conveyor's second section pre-stores empty bottles before they are needed, allowing the blowing equipment to continue producing bottles during filling line stoppages. This preliminary storage action prevents both scrap generation and production interruption, as bottles are already prepared and staged for immediate resumption of filling operations.
3Quantity of substance
If buffer conveyor second section stores bottles during normal operation, then storage capacity is wasted, but if empty it cannot buffer stoppages
Solution Approach 1:
The buffer conveyor is designed as a multi-functional system where the same structure serves different purposes based on operational mode: during normal operation, it functions as a transfer conveyor moving bottles efficiently; during stoppages, the second section automatically functions as a buffer storage. This universality eliminates the trade-off between storage capacity and operational efficiency.
Data Source
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AI summary
Disclosed is a facility for producing bottles of liquid product, the bottles being formed from thermoformable plastic, the facility comprising a device for blowing (1) bottles from preforms (9), with a heating channel (8), a filling and finishing line (3), comprising bottle filling, sealing and/or capping stations, with a buffer conveyor (2) interposed between the blowing equipment (1) and the filling and finishing line (3), formed mainly as an endless conveyor capable of receiving bottles, the buffer conveyor comprising a first section (T21) used under normal flow conditions, and a second section (T22), complementary to the first section and serving as buffer storage space under unplanned shut-down conditions of the filling line, the bottle storage capacity (7), for the second section (T22), being at least equal to the number of bottles and preforms which can be received in the blowing machine including the heating tunnel.