High Speed Bottling Automation Processes Ben Spence December 5, 2012

Overview: Current State Introduction (0:01-0:45sec) over 500 brands more than 1,200 bottling plants all over the world nearly 10,450 soft drinks from Coca-Cola are consumed every second of every day 1.6 billion times a day someone reaches for a Coca-Cola product 800,000,000 servings of just Coke everyday Operate in 206 countries (more countries than the UN) Billions of plastic bottles, aluminum cans, glass bottles

Overview: Where Used Bottling Process (7:30-8:50) (click here) 24 hours a day 7 days a week One plant can make 500,000 preforms every hour

Who uses, what used for, when used Coca-Cola Company All other soft drink companies Food Industries Medical Devices Other containers etc.

Costs Injection Molding Presses Depends on: Injection Molds Small (1-5 tons) $30,000-$200,000 Medium (5-200 tons) $200,000-$400,000 Large (200-1000 tons) $400,000 and up Injection Molds Simple $20,000-$50,000 Complex $50,000-$1,000,000 Depends on: number of cavities size of the parts and molds complexity of the pieces expected tool longevity surface finishes forces needed

Required Supporting Technology Vacuum Systems Compressed Air Systems Heating Systems Material Handling Robots Conveyors Sensors Controls AGVs PLCs Vision Systems Bottles being formed (11:50-12:40)

References http://answers.yahoo.com/question/index?qid=1006032 315828 http://en.wikipedia.org/wiki/Injection_molding http://www.youtube.com/watch?v=dVfUo6NzTKE&featur e=youtu.be http://imoldmaking.com/injection-molding/how-much- does-a-mold-cost/ http://www.asminternational.org/content/ASM/StoreFile s/06560G_Sample.pdf http://www.gerresheimer.com/en/products- services/pharma http://www.pmolds.com/

Application Rules and Limitations Forces Drives Temperatures (heating and cooling) Time to heat and cool Material properties Size of parts Complexities of parts

Primary Vendors

Existing and Evolving Standards Tonnage (Speed/Capacity) Forces get higher to do larger shots Some presses now are rated to 15oo tons Size Larger presses mean larger parts are being injection molded Tolerances As tight as 0.00001” possible on some machines Complexity Parts with undercuts, threads Surface Finishes Fine surfaces Textured surfaces

Technical Paper http://www. asminternational Molding compounds and their affects on screw injection molding machines Relationship between material properties and injection press selection

How Integrates with Process Raw materials in Vacuum systems Screw drive feeders Injected components out Robots Conveyor belts AGVs

Class Application Your company is developing a new plastic container and you have been tasked to organize the injection molding presses. You must decide between 2 injection molding press options. Option 1: A very large press with a high tonnage rating that would be able to hold a mold that makes 20 containers. It takes more energy and time to heat the mold so the cycle rate is about 15 seconds. Option 2: Two smaller presses with lower tonnage ratings that are able to hold molds for 5 containers. Since the molds are smaller they take less time to heat so the cycle rate is 7.5 seconds. Consider the Pros/Cons of each method. Assume that the cost of the press and molds is equivalent.

Class Application-Discussion Option 1: Pros Less support equipment Only one mold Less operators Cons Down time is critical Higher forces wear molds faster Option 2: Pros Simpler cycle Less power If one goes down you can still produce Cons Two molds More support equipment

Summary Injection molding is a highly automated process for producing plastic bottles Costs depends on: Limitations number of cavities Forces size of the parts and molds Drives complexity of the pieces Temperatures (heating and cooling) expected tool longevity Time to heat and cool surface finishes Material properties forces needed Size of parts Complexities of parts Required Supporting Technology Evolving Standards Vacuum Systems Compressed Air Systems Tonnage (Speed/Capacity) Heating Systems Size Material Handling Tolerances Robots Complexity Conveyors Surface Finishes Controls/Sensors AGVs