Optional Features:
Blocked Neck Bore Detection ¦ Top Load Strength
Measurement ¦ Height Measurement ¦ Flash In Handle ¦ Colour
Measurement Translucency/Opacity Tester ¦ Vision Systems ¦ Automatic “Self-Test” ¦ Automatic “Self-Test” ¦ Automatic Weight Correction
¦ Scrap Count Correction
We would love to tell you that the huge range of optional features we offer were all our idea, but the truth is that 80% were simply requests from customers that were then incorporated as standard options! We make on-line leak testers, primarily for plastic containers. It is our goal to try and do every test that is possible within the available cycle time. For over 20 years we have been offering a complete test and automation solution for containers from small bottles to 'L' ring drums. It started with the simplest option - a blocked neck bore test. Next we integrated the top-load strength test and container height measurement. Then we added flash-in-handle detection, container weight and colour measurement. Virtually every new tester we're shipping has an SD memory card fitted to log the leak test results, container weight and container serial number. We're even interfacing to pin-marking machines - the best way to put information on a drum! We will shortly be adding automatic wall thickness measurement at critical points on the container - invaluable for UN containers. Again, this information will be stored on the memory card to give a complete test record - perfect for proving the container was produced correctly.
OPTIONAL TEST FEATURES THE GOAL . . . TO PROVIDE 100% AUTOMATIC QUALITY CONTROL
In addition to holes, the blow moulding process can produce a variety of other defects that adversely affect the quality of the moulded product. In the past it has been acceptable to rely on operator inspection to check for these problems, but in an increasingly competitive environment, this is a luxury few companies can afford. With the addition of a few sensors, a leak tester can perform a number of extra tests that will help ensure that the mouldings you sell are 100% to your customers specification. New sensors are continually being developed and the list of optional features will continue to grow as these new devices are incorporated into our testers. Your expectations as to what you require from down stream testing equipment is important to us, particularly as virtually all the optional features listed below were developed as a result of customer requirements.
Blocked Neck Bore Detection
This is the simplest and most popular addition to all makes of leak testers and is available in two basic forms:
- Mechanical Sensor - Low cost - can be fitted to any leak tester
- Electronic Sensor - More accurate - less prone to jamming and enables a better reject analysis
Top Load Strength Measurement
The force applied by the leak test head will always cause the bottle to
collapse by a small amount, and this movement can be measured by a linear
position transducer. If the collapse exceeds an operator set value then the
container is rejected. We also offer a much more sophisticated system that
lowers the test head onto the bottle neck with a low force, automatically sets
this as 100% and then applies the correct force for the top load test. A
digital readout displays both the bottle deflection
and the applied force.
Height Measurement
Although container height measurement is provided by the top load strength system a much simpler system is available that uses a photocell beam set just above the “normal” bottle height. This is useful for detecting if neck flash is still present.
Flash In Handle
The possibility that some part of the blow moulding process is incomplete is one of the reasons that full automation (“lights out” production) is still proving to be impractical for many companies. Residual flash and other unfinished operation can usually be detected by simple photo cell techniques.
Colour Measurement
There are many photocells on the market that can compare a containers colour to a previously “taught” reference. This can give an early warning that the colour concentrate (masterbatch) is running out. It can also be used to detect missing or misplaced labels by checking that a particular colour on the label is in the correct place.
Translucency/Opacity Tester
There are occasions where it is important that a container is sufficiently opaque e.g. to prevent the end user from seeing the “fill line”. There may be other applications where the container should be clear enough to see the contents e.g. photo copiers detect that the toner is low by shining light through the toner container. Conventional photocells perform this task reliably and are easily added to the leak tester.
Vision Systems
The continual progress in micro-electronics is bringing down the cost and increasing the capabilities of vision systems to the point where they can now be applied to detecting many common container defects. We have evaluated many systems on the market and have some serious reservations about the user friendliness of the operator interface. See our technical bulletin BM005 for further information.
Automatic “Self-Test”
Our “self-test” system works by automatically opening a calibrated orifice into the container and monitoring the successful rejection of the “faulty” container. The test can be set to operate at any frequency e.g. once every 10, 100 or “N” A simple system with a manual tap and orifice can also be supplied. This is particularly suitable for manually loaded testers.
Automatic Check Weighing
If it is important that you don’t ship containers outside the customers weight specifications, then you will appreciate that this system will automatically reject any container not within the limits you set. We can offer both static and dynamic weighing (weighing the container on a moving belt) to enable automatic weighing from normal to high speeds.
Automatic Weight Correction
Our weighing systems have the capability of sending a correction signal to the machines die gap control circuit to maintain the container weight within tight limits. This can save material by allowing you to run nearer to “bottom limit” , and get more consistent performance from the blow moulding machine and other downstream equipment. We are the sole worldwide licensees to the Krupp-Kautex patent which covers the basic principle, and in addition we have patented a unique method of interfacing to the machines parison programmer.
Scrap Count Correction
Our leak testers all provide a count of passed containers and an analysis of the number of containers failed and the reason for failure. These counts can be manually modified if for example some containers are subsequently found to be ”saleable” . This feature is normally password protected.