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The automatic bottle unscrambling machine is an integral component of any packaging line, especially for industries that handle large volumes of bottles. Its primary purpose is to orient and place bottles on a conveyor belt in the correct order for subsequent filling, capping, and packaging. Several types of bottle unscramblers are available to cater to different bottle shapes, sizes, and production requirements.
Rotary Bottle Unscramblers:
One of the most common bottle-unscrambling machines is rotary. It uses a circular picking-up table that offers a station to receive the bottles from the feed rail, reorients them, and then drops them onto the conveyor for further processing. The main advantage of this bottle unscrambler is that it does not have to stop as the reorientation of the bottles happens at a constant speed. This Rotary bottle unscrambler works best for round bottles of different heights and sizes.
Starwheel Bottle Unscramblers:
This mechanism works as a bottle feeding system. Randomly oriented bottles are turned into singulated, aligned bottles through star-shaped wheels. The starwheel can be customized in size and shape depending upon the bottle used. The major benefit of the Starwheel unscrambler is that it is compact, and as a result, the overall footprint of the machine is less than other unscramblers. However, one disadvantage the starwheel has is that it is only suitable for cylindrical bottles. Furthermore, it can also only achieve a maximum speed of 100 bpm.
Spiral Feeder Bottle Unscrambler:
This kind of bottle unscrambler is more complex and consists of a bowl feeder and a pick-and-place mechanism. The bowl feeder uses spiral tracks to invert or orient bottles before they are dropped onto the conveyor belt through the pick-and-place mechanism. The main advantage of this kind of configuration is that it is suitable for round, square, and even ovoid-shaped bottles of all sizes. Furthermore, high-speed operations of more than 200 bpm are possible with this kind of configuration.
Sorting Speed:
The ability to sort out and put containers on a filling line is known as the sorting speed. The sorting speed for bottles that automatic bottle unscramblers can handle is usually between 200 and 900 containers per minute. The specific sorting speed depends on the model and features of the machine.
Power Requirements:
The power requirement indicates how much energy the machine will use and the type of energy it needs to function. Power needs for bottle unscramblers are classified by electric power of 1 to 3 kW and by operating voltage, which ranges from 200 to 480 volts.
Machine Size:
The size of the machine shows its height, length, and width. For industrial use, the length is about 2 to 4 meters, the width is about 1 to 3 meters, and the height is about 1 to 2 meters. The precise size of the machine will depend on its design and capacity.
Bottle Types:
Automatic bottle unscramblers can deal with bottles of various forms and sizes. This includes cylindrical, square-shaped vessels, and bottles of varying sizes. Square bottle unscramblers are expertly designed to accommodate square-shaped bottles. They feature feed systems and guidance mechanisms adapted to the distinct geometry of square bottles.
Smoothing Technology
A bottle unscrambling system's capacity to segregate and classify bottles of various shapes and sizes depends heavily on its sorting technique. The vibration sorting method is widely employed; its sophisticated feeding system and vibrating boards can efficiently sort bottles with various heights, diameters, and forms and are well-suited for bottles with irregular shapes and sizes.
Lubricate moving components:
To keep the machine running well and smoothly, it's essential to oil the moving parts, like bearings and chains, regularly. This helps avoid friction-related wear and tear, which can reduce the machine's lifespan.
Keep it clean:
Wipe the machine with a towel and warm, soapy water frequently to eliminate any bottle leftovers and dirt. Cleaning the machine helps prevent clogging and breakdown of the components.
Check the electrical parts:
Look over the electrical parts, such as cables and connections, regularly. Ensure everything is tightly connected, insulated correctly, and free of any harm or wear, and fix any damaged components right away to guarantee a steady electric supply.
Check the air source:
Maintain the air source by checking the compressor and air hoses to see if there are any leaks or air pressure drops. Ensure there is enough air pressure for the machine to function well.
Multilang
Pharmaceutical and chemical industry:
Automatic bottle unscramblers are widely applied in the pharmaceutical and chemical industries to sort out bottles of varied shapes and sizes for filling, labelling, and packaging. These include pill bottles, syrup bottles, and chemical containers. These machines ensure high efficiency and accuracy in arranging bottles, which is important since misplaced containers can lead to wrong medications or toxic substances.
Food and beverage industry:
In the food and beverage industry, automatic bottle unscramblers can be used to handle large volumes of bottles for milk, juice, condiment, and water, among other drinks. These machines ensure high-speed, error-free unscrewing, which helps production lines run seamlessly without holding up bottle-sorting processes.
Cosmetics and personal care industry:
Cosmetics and personal care products come in all sorts of bottles and jars, from tall and slender to short and round. Automatical bottle unscramblers handle this variety, getting products like lotions, shampoos, and make-up containers into the filling machines quickly and efficiently.
Chemical and petrochemical industry:
Petrochemical products, such as motor oil and lubricant, come in diverse shapes and sizes. Also, chemicals used in agriculture and other fields can also be very variable. Automatic bottle unscramblers help to cope with this product variety, making sure that bottles like these get to the filling area without delay.
Medical and healthcare industry:
Vaccines and other drugs are often supplied in specific bottles and with precise labelling requirements. Automatic bottle unscramblers work to ensure that these sensitive products are handled correctly and get to where they need to be without delay.
Filling and packaging services:
Contract manufacturers and packaging services fill for various clients and have to cope with a wide range of bottle types. Automatic bottle unscramblers are essential in allowing these companies to provide a responsive service at high speed and with low costs.
When investing in an automatic bottle unscrambling machine for production lines, it is essential to examine the machine's sorting capability and flexibility, bottle feed system, orientation mechanism, and integration and automation features.
Sorting capability and flexibility:
When selecting a suitable machine, it is essential to ensure that its sorting capacity matches the production requirements. The machine should efficiently handle the specific bottle types, sizes, and shapes used in the production line. Additionally, the unscrambler should be flexible and adapt to changes in bottle specifications to accommodate future modifications without excessive downtime or reconfiguration.
Orientation mechanism and bottle feed system:
A suitable bottle unscrambler has a convenient feeding system that has the potential to minimize manual intervention and enhance operational efficiency. Furthermore, the machine's orientation mechanism should ensure accurate positioning of bottles for subsequent filling or labeling operations.
Integration and automation:
For enhanced operational efficiency, it is essential to aim for seamless integration between the bottle unscrambler and other production line components, such as conveyors, fillers, and cappers. Additionally, the incorporation of automated features, such as sensor-based detection and control systems, can enhance the machine's overall performance and reduce the need for manual handling.
Q1: Can an automatic bottle unscrambling machine handle different types of bottles?
A1: Yes, but not all. Some automatic bottle unscrambling machines may be able to handle different types of bottles. However, they may require bottle-specific change parts to accommodate various shapes, sizes, and weights.
Q2: What are the safety features of an automatic bottle unscrambling machine?
A2: Automatic bottle unscrambling machines may have safety features like emergency stop buttons, protective guards, safety interlocks, and overload protection.
Q3: Do automatic bottle unscrambling machines require lubrication?
A3: Yes. However, guidance from the manufacturer should be followed regarding the type of lubricant to be used and the frequency of lubrication.
Q4: Can the speed of an automatic bottle unscrambling machine be adjusted?
A4: Yes. The throughput of these machines can also be adjusted, but it may depend on the specific design and model of the bottle unscrambling machine.
