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FMS
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The Filtec Filler
Management System (FMS) is used to maximize filler performance, reduce
product loss, minimize maintenance related downtime, and increase
production line efficiency. |
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System Concept
The Filler Valve Monitor utilizes an Inspection Head mounted
over the transfer conveyor between the filler and the seamer, which
gives the system the ability to check the filling characteristics of
each filler valve at a fixed level and in a quantitative manner. The
fill level history of each valve is stored in computer memory and is
readily available to the operator for maintenance purposes. By
using various sensors, the Filler Valve Monitor system can
accurately track cans from each filler valve, through the seamer and
down the reject station.
 | Filler Monitor Inspection Head
The only system on the market today that provides a separate
lowfill inspection beam for immediate detection of lowfilling valves
for automatic filler shutdown. The operator is also alerted if any
valve appears to be erratically lowfilling. All lowfilling valves
are clearly shown on the Current Shift Screen. |
| Lowfill Inspection System
The filler operator is immediately notified when a lowfilling
valve is detected. The valve number and the quantity of lowfills are
clearly displayed on color screen. |
| System Computer and PLC Interface
- RS-232/422/423 Serial Output – Provides Production, QC,
and Diagnostic information to a host computer or PC on the plant
floor. Enables the user to reset all system counters remotely.
- Programmable Logic Controllers (PLC) – Allows FT-100 to
interface with the plant PLC for greater line control. As an
example, the filler may be shut down when too many lowfills are
being detected. |
Quantitative Analysis
| Optional Quantitative Analysis (QA) Inspection Beam
- The 16 lowest filling valves are automatically selected by
the system and may be displayed for quick reference by maintenance
personnel.
- The 16 highest filling valves are also available so
maintenance may rework them when time permits, thus reducing product
giveaway. |
| All Valves Sorted By Fill Level
All filler valves are quantified by relative fill level,
ranging from lowfills to highfills, and shown on one screen for ease
of troubleshooting and maintenance. This screen allows the operator
to observe the average fill level point for the entire filler
relative to each valve. |
| Histograms of Selected Filler Valves
For the first time ever, maintenance personnel can visually
observe the actual filling characteristics of each valve on the
filler. With experience, these Histograms can be used as
"diagnostic indicators" for valve repair, thus identifying
specific valve problems and greatly reducing maintenance time. |
| Optional Production Efficiency Monitoring
Production Efficiency Monitoring (PEM) graphically plots
filler speed versus time for each shift. At the end of each shift,
PEM displays total containers produced, elapsed run time, actual
average filler speed, total lowfills, target filler speed, and the
actual filler speed achieved over the entire shift. Overall Filler
Efficiency is also calculated and displayed as a percentage of
target speed. PEM allows management to identify the exact time and
length of any downtime periods so that corrective action may be
taken, thus increasing overall production efficiency. |
| System Diagnostics and Alarms
- System Diagnostic Messages are used to assist in rapid
troubleshooting which reduces maintenance related downtime.
- Valve Lowfill Alarm warns the operator when any particular
valve is producing too many lowfilled cans in a predetermined number
if filler revolutions. Immediate action can then be taken to
eliminate this lowfill problem.
- Total Lowfill Alarm warns the operator and stops the filler
when an excessive number of valves are causing lowfilled cans.
- Seamer Jam Alarm stops the filler/seamer almost immediately
after a jam in the seamer is detected which reduces time to clear
jammed cans, decreases product loss, and minimizes possible damage
to the seamer components.
- Alarm Status
- Warning and alarm messages flash on status line
- Sensor Pulse Widths
- Performance of all system sensors is constantly monitored
and displayed
- Sensor Inputs
- Displays the status of all system sensors |
Rejection
| Sure Sync Synchronization
Accurate Synchronization: Before each sampling cycle is
activated, a can from a selected seamer head is coded with a small
amount of invisible, water soluble Ultraviolet (UV) fluid. The UV
sensor, mounted just in front of the rejection system, detects the
coded can and sends a synchronization signal to the computer
verifying that the proper can is in position for sampling. |
| ProLine Impulse Rejector
The ProLine Impulse Rejector, supplied with the Filler
Valve Monitor, will sample individual cans at speeds up to 2500 per
minute. |
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| Automatic Sampling
The system will remove cans from the line at full
production speeds, thus eliminating sampling downtime and increasing
overall efficiency by 2 to 3 percent. |
| Best Average Valve Sampling
The Filler valve Monitor automatically selects the
filler valve that is filling closest to the Average Fill Point of
the filler and removes cans filled by this valve for evaluation
purposes. |
| Lowfill Reduction
Results in large savings by greatly reducing the
underfills rejected by the downstream fill level devices. |
| Overfill Reduction
Reduces product giveaway by instantly showing
overfilling valves and valve histogram trends that lead to
overfilled containers. |
| Seamer Jam Alarm
Instantly stops filler/seamer when jams occur which
reduces downtime to clear jammed cans. The Seamer Jam Alarm function
also minimizes damage to the seamer components and decreases product
loss. |
| Reduction in Filler Maintenance Costs
Warns maintenance of valve problems before they
generate underfills or overfills. Costly valve replacement/rotation
programs may be eliminated so only faulty valves are changed. |
| Filler Operator
By implementing the various alarms and automatic
stop features offered on the Filler Valve Monitor, the filler
operator may be used to run several fillers or other pieces of
equipment on the production line. |
| Operate Filler at Higher Average Speed
By peaking valve performance and monitoring overall
filler capabilities, the filler may be operated from 5% to 10%
faster without producing excessive underfilled or overfilled
containers |
| Production Efficiency Monitoring
Provides plant personnel with a graphic display and
numerical summary of the filler’s last shift performance and
efficiency, allowing them to identify the causes for line downtime. |
| Optional Sampling Diverter
The FS-130 SS Sampling Diverter
allows plant personnel to sample individual cans or consecutive
revolutions of the filler/seamer without stopping the production
line. As a result, sampling related downtime is greatly reduced
giving a significant increase in production efficiency. The system
will operate up to 2200 cans per minute. |
| Optional Slat Rejector
The LS-3 Slat Rejector
provides synchronized rejection and sampling up to 72,000 containers
per hour and is particularly effective for small containers or where
spilling is a concern. |
| Seamer Monitor
- The Seamer Monitor is a quality assurance and a
preventative maintenance tool, which may be installed with the
Filler Valve Monitor or incorporated later. By rapidly detecting
catastrophic chuck failures, the Seamer Monitor could pay for itself
on the first day of operation, since no one can predict when such
failures will occur.
- By Monitoring each chuck on a continual basis, the high
sensitivity and long-term stability of the Seamer Monitor inspection
system allows it to detect minute chuck imperfections and alerts
maintenance personnel before failure occurs. By using the Seamer
Monitor in this preventive maintenance mode, suspected chucks are
replaced before the integrity of the can seams are jeopardized.
- Maintenance personnel must no longer replace seaming chucks
on a routine basis, but only when the Seamer Monitor detects any
signs of minute damage that can cause potential leakage problems.
This greatly increases the effective life of the chucks and reduces
maintenance costs. |
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The FVM was
specifically designed for use in the beverage industry by both skilled
and unskilled operators. Several years of intensive field testing have
resulted in a system that is now universally accepted by Management,
Quality Assurance, Maintenance, and Machine Operators. By integrating a
Color Touchscreen operator interface, the system does not intimidate the
user. In fact, plant personnel enjoy using the unique features of this
equipment:
| Reduces training time and dependence on trained operators. |
| No buttons, switches, keyboard, or lightpen. Just touch the
appropriate highlighted message block on the Touchscreen for instant
access and adjustment of the system |
| System functions are displayed and adjusted by use of the
Touchscreen. The FT-100 "speaks" the language of the
operator, be it English, French, German, or Spanish |
| Interfaces with the filler/seamer for rapid shutdown in
case of seamer jams or excessive filler valve problems |
| SUPER FILTEC screen gives direct access to most commonly
used functions |
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