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Rinser Filler Capper Solutions for Beverage Packaging

Bottle filling machines are an all-in-one system with bottle rinser, filler, and capper (RFC). RFC machines as a whole are meant to protect product from damage, contamination, and spoiling. These machines frequently handle large amounts of bottles that come in a variety of shapes, sizes, and colors. 

Rinsing empty bottles before moving onto the filling station is an incredibly important step because it helps prevent contaminated product from being distributed. From there, the filling mechanisms of the machine need to make sure that the correct amount of product is put into each bottle to maintain brand consistency. And the last step, the capper, needs to create a reliable seal on the bottle to make sure that liquids do not leak and a high-quality end product is delivered to each consumer. Failure to clean, fill, or seal bottles properly could lead to potential recall and wasted product, which can cost companies a great deal. 

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RFC machines on beverage lines need to be suitable for high-pressure and high temperature washdowns, have quick response times for a high-speed environment, and be low maintenance. Finding the best automation equipment for these machines greatly increases a factory’s output without adding additional labor and overhead costs.

Banner Engineering offers a wide variety of products that have environmental ratings up to IP69K and can withstand the harsh environments that the bottling industry is used to. Banner provides automation solutions for container detection, cap sorting and placement verification, fill level verification, slip ring replacement, and improve overall equipment effectiveness (OEE). Our products are versatile and reliable, which means the machines can be easily adapted to meet the needs of a highly competitive beverage market. 

Featured Applications

Clear Container Detection in a Clean-in-Place Rotary Filler
Clear Container Detection in a Clean-in-Place Rotary Filler

Track bottles as they move through the rotary filter.

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Cap Sorter Detection
Cap Sorter Detection

Banner’s R55F fiber optic sensors have the capability to detect the presence of caps regardless of their color or size – a clear advantage in an industry that has a wide variety of bottle caps and frequent line changes. In this type of application, the fiber optic sensors are used to recognize long pauses between the caps which would then signal a jam to the operators of the machine. The fibers are compact and can be easily mounted in confined and typically inaccessible spaces.

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Identifying Presence and Height of a Bottle Cap
Identifying Presence and Height of a Bottle Cap

The iVu Plus Gen 2 vision system, paired with a Q4X and LEDRB backlight, offer a solution that will provide dependable results.

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Non-Contact Fill Level Verification
Non-Contact Fill Level Verification

Banner’s QS30H2O sensor is a specialized sensor developed to address challenges with sensing the presence of water and water-based liquids. The QS30H2O operates in a through beam sensing mode and the emitter uses a wavelength that is tuned to not pass through water. The high excess gain of the sensor makes it powerful enough to see through an assortment of plastic and glass containers. Two pairs of sensors can be utilized to determine that the fill level has met minimum but is not overfilled and wasting product. Apertures can be placed on the receiver end to minimize the beam pattern and increase accuracy of the application. This ensures products that do not meet fill level criteria are not processed or shipped.

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Slip Ring Replacement with Wireless Solutions
Slip Ring Replacement with Wireless Solutions

Slip rings are subject to constant movement which in turn leads to continuous maintenance in order to avoid degradation of the rotating electrical connection caused by normal wear and debris. Slip ring failure bring production to a halt, resulting in unexpected and costly downtime. The DX80 wireless radios provide a non-contact solution for transmitting the sensor signals from inside the filler bowl to the control panel. The wireless node located on the rotary filler can be battery powered thus providing power to the sensors for a wire-free installation. The DX80 wireless solution eliminates the need for slip rings, helping to decrease downtime and maintenance.

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Vent Tube Presence on Filler [Success Story]
Vent Tube Presence on Filler [Success Story]

The rotary fillers dispense beer into bottles traveling at speeds of up to 900 bottles per minute. The company needed a solution capable of detecting spreader washers on the vent tubes as well as loose or missing tubes. However, the movement of the rotary filler and the wet washdown environment made close proximity deployments difficult and the range required for a remote solution could compromise inspection reliability.

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