1. High Speed Bottling Automation Processes
Ben Spence December 5, 2012

2. Overview: Current State
Introduction (0:01-0:45sec)
over 500 brands
more than 1,200 bottling plants all over the world
nearly 10,450 soft drinks from Coca-Cola are consumed every second of every day
1.6 billion times a day someone reaches for a Coca-Cola product
800,000,000 servings of just Coke everyday
Operate in 206 countries (more countries than the UN)
Billions of plastic bottles, aluminum cans, glass bottles

3. Overview: Where Used Bottling Process (7:30-8:50) (click here)
24 hours a day
7 days a week
One plant can make 500,000 preforms every hour

4. Who uses, what used for, when used
Coca-Cola Company
All other soft drink companies
Food Industries
Medical Devices
Other containers etc.

5. Costs Injection Molding Presses Depends on: Injection Molds
Small (1-5 tons)
$30,000-$200,000
Medium (5-200 tons)
$200,000-$400,000
Large ( tons)
$400,000 and up
Injection Molds
Simple $20,000-$50,000
Complex $50,000-$1,000,000
Depends on:
number of cavities
size of the parts and molds
complexity of the pieces
expected tool longevity
surface finishes
forces needed

6. Required Supporting Technology
Vacuum Systems
Compressed Air Systems
Heating Systems
Material Handling
Robots
Conveyors
Sensors
Controls
AGVs
PLCs
Vision Systems
Bottles being formed (11:50-12:40)

7. References http://answers.yahoo.com/question/index?qid=1006032 315828
e=youtu.be
does-a-mold-cost/
s/06560G_Sample.pdf
services/pharma

8. Application Rules and Limitations
Forces
Drives
Temperatures (heating and cooling)
Time to heat and cool
Material properties
Size of parts
Complexities of parts

9. Primary Vendors

10. Existing and Evolving Standards
Tonnage (Speed/Capacity)
Forces get higher to do larger shots
Some presses now are rated to 15oo tons
Size
Larger presses mean larger parts are being injection molded
Tolerances
As tight as ” possible on some machines
Complexity
Parts with undercuts, threads
Surface Finishes
Fine surfaces
Textured surfaces

11. Technical Paper http://www. asminternational
Molding compounds and their affects on screw injection molding machines
Relationship between material properties and injection press selection

12. How Integrates with Process
Raw materials in
Vacuum systems
Screw drive feeders
Injected components out
Robots
Conveyor belts
AGVs

13. Class Application
Your company is developing a new plastic container and you have been tasked to organize the injection molding presses. You must decide between 2 injection molding press options. Option 1: A very large press with a high tonnage rating that would be able to hold a mold that makes 20 containers. It takes more energy and time to heat the mold so the cycle rate is about 15 seconds. Option 2: Two smaller presses with lower tonnage ratings that are able to hold molds for 5 containers. Since the molds are smaller they take less time to heat so the cycle rate is 7.5 seconds. Consider the Pros/Cons of each method. Assume that the cost of the press and molds is equivalent.

14. Class Application-Discussion
Option 1:
Pros
Less support equipment
Only one mold
Less operators
Cons
Down time is critical
Higher forces wear molds faster
Option 2:
Pros
Simpler cycle
Less power
If one goes down you can still produce
Cons
Two molds
More support equipment

15. Summary Injection molding is a highly automated process for producing plastic bottles
Costs depends on:
Limitations
number of cavities
Forces
size of the parts and molds
Drives
complexity of the pieces
Temperatures (heating and cooling)
expected tool longevity
Time to heat and cool
surface finishes
Material properties
forces needed
Size of parts
Complexities of parts
Required Supporting Technology
Evolving Standards
Vacuum Systems
Compressed Air Systems
Tonnage (Speed/Capacity)
Heating Systems
Size
Material Handling
Tolerances
Robots
Complexity
Conveyors
Surface Finishes
Controls/Sensors
AGVs