High efficiency and low consumption are the common expectations of all manufacturers for production equipment. The Coca-Cola West-Zentra makes this ideal a reality thanks to the high-efficiency filling line of Krones' disposable PET bottles. The evaluation of the filling equipment is: high efficiency and low consumption, requiring few operators, and thus can reduce many costs.

Headquartered in Berlin, Coca-Cola Beverages is responsible for the filling and sale of Coca-Cola products in most parts of Germany. Despite the company's majority stake, Dorsten's West-Zentra Cool Beverages is still an independent company.

Due to the optimistic application prospect of disposable PET bottles in the refreshing beverage industry, West-Zentra invested heavily in this type of filling equipment, and purchased 1.5 liter PET bottles and volumetric quantitative filling machines with a Krones output of 24,000 bottles/hour. The production of 40,000 bottles per hour of PET bottle filling equipment and a production line of 36,000 bottles / hour. West-Zentra is particularly pleased with the performance of the last production line.

36,000 bottles / hour production line

Lowest energy consumption

“Krones assures us that the maximum energy consumption of this 36,000 1.25 liter bottle line per hour will not exceed 850 KWh.” Peter Krebs, General Manager of West-Zentra, said: “But actually better. After more than a year of operation. After that, we measured the actual energy consumption of only 605 KWh. This value is really unbelievable. It means that hundreds of thousands of euros can be saved every year. If you consider the rising energy price, this is really a considerable amount. Look, the first investment is a little higher, which is second."

In order to ensure a low total energy consumption, Krones equipment is generally designed with energy efficiency. In particular, the Contiform S-type equipment with the Air Wizard system can save a lot of energy. On the one hand, the blow molding pressure required for production is reduced, and on the other hand, the production of blown air is recycled, so that a part of the blown air is used for pre-blowing and stretching in the pressure release stage.

Efficient use of production lines

In addition to energy consumption, the second focus is high efficiency and reliability. At the time of acceptance, the production line has a working efficiency of nearly 96%. And practice has proved that the average work efficiency has been above 90%.

The third focus is on "Line Utilization." The effective use of the production line averaged 15 shifts (including a start-up, shutdown and cleaning shift), and the best-use production line reached 81%. The main reason is that the equipment adjustment time is extremely short. It takes only ten minutes to re-reach the operational state after each replacement of the item and flushing, while the other existing West-Zentra production line takes 30 minutes. According to Peter Krebs, everything is attributed to Krones' new Contiflow mixer. This line puts all common Coca-Cola products into 1.25 liter and 1.5 liter bottles. It takes only 29 minutes to replace the bottle specification, and double the time in other existing equipment. Thanks to the new Krones quick change system, it takes only 45 minutes to adjust the bottle size from 1.25 liters to 1.5 liters, and nearly two hours for other existing equipment.

Since the servo technology, it has only one person to adjust the Robot 3A stacker to another layer, and within five minutes. Maintenance manager Jörg Söchhtig added: "Servo drive technology can also greatly reduce equipment wear." The stacker can complete two Düsseldorf-style half-turns every 40 seconds, which is a European-style seesaw. To this end, the Robot 3A is equipped with two slab preparation stations. It rotates between the two preparation stations while loading two half-plates at a time. After the two halves are integrated, they are wrapped by two slab wrappers and sent to the submission. The forklift picks up eight half-twist plates at a time, each with four layers of 1.25 litre six bottles or 1.5 litres four bottles.

Very few operators required

One of the many advantages is that the entire filling machine no longer requires four people per shift, but only 2.5 people. Among them, one person is responsible for the drying process. Operating a filling machine requires only a “half” individual, as he can also be responsible for another filling machine. The remaining one can operate both the labeler and the blow molding machine.

Stretch blow molding technology concentrates on one workshop

Coca-Cola West-Zentra concentrates all stretch blow molding technology on three PET lines in a single workshop. The workshop has Krones Contiform blow molding machines manufactured in different generations. The two old Compact 16 and 20 Series Contiform blow molding machines have an hourly capacity of 20,500 0.5 liter bottles and 28,000 1.0 liter bottles. Another Contiform S16 blow molding machine installed in 2002 can blow 24,000 0.5 liter bottles per hour. The new line is equipped with a Contiform S20 blow molding machine with a blow molding model quick changer. The capacity of each cavity of this machine reaches 1800 bottles per hour. “This is the most efficient blow molding machine I have ever seen,” Peter Krebs admires. “The machine is easy to operate and reliable, and it went smoothly from the start.” When it comes to West-Zentra's reason for using only Contiform blow molding machines, He explained: "Since its effect is very good, there is no need to switch to other machines. Another positive factor is that Krones Academy is ideal for providing machine operator training."

Dry pre-labeling effect is good

Close to the Contiform S20 blow molding machine is a Contiroll HS High Speed ​​ring labeler. The newly blown PET bottles are sent to the ring labeling machine via the Air Conveyor air conveyor. “Dry labeling is only good and harmless,” explains Jörg Söchhtig. “The labeling machine has been in use for several years and still looks like new. The blow molding machine and the labeling machine are perfectly placed, saving us manpower. The construction is simple and easy to clean. The servo drive guarantees that it is very reliable. It is very simple to use the new operation panel and the machine actually adjusts automatically."

Pre-labeled bottles are transported from the packaging shop to another filling station via the Air Conveyor air conveyor. The VODM-PET volumetric quantitative filling machine and the bottle washer are combined with the servo capping machine and placed on a ramp with a good hygienic environment. “The treatment is very clean. The Krones filling machine is open and easy to operate. Since the flushing system is cleaned every time the job is suspended, we can almost eliminate the weekend cleaning work on Saturday.”

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