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Glass breakage procedure in a fast-paced bottling plant


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Landi Pelser

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Posted 18 June 2020 - 12:04 PM

I work in a fast-paced, semi-automated bottling plant. The filling area is enclosed and operated by a bottling operator, thus if a bottle breaks or bursts inside that area, the system is set to deliberately under-fill (reject) bottles on the conveyor before and after the burst, as well as to do a spray rinse of the area. 

How does one validate and verify that such a procedure is effective? it would be impossible and uneconomical to place the whole area and personnel on hold just because a bottle broke, (which can happen frequently), as per the normal/strict glass breakage procedures and templates I've seen.

 

Any recommendations, examples or templates would be much appreciated? 



SQFconsultant

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Posted 18 June 2020 - 12:43 PM

Why does this happen so often?

 

I'd be looking to the root cause first.

 

In the past we had a high-speed glass (soda) bottling facility that used an led scanner to check the bottles prior to fill - close to 100% nixies were isolated and dropped out the bottom of the machine and the fillers only had one or two bottles break a week in which case they auto stopped the line for clean up, inspection and release back to production.

 

I'd be more interested in finding why this happens so often first.


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Landi Pelser

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Posted 18 June 2020 - 12:55 PM

Thanks for you input Glenn - I'll definitely go back and firstly check our specs with the supplier to determine root cause. 

 

My question is then, once a bottle breaks by the filler, how do you validate and verify that the automatic cleaning system was sufficient?

Small glass shards are not always visible when doing a visual inspection inside a bottle. 

 

Regards.



AmeliaJacobs

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Posted 14 January 2022 - 11:45 AM

I'm curious as to whether or not you've found any resolution.

 

i'm working in a bottling plant now and I'm fairly new to this sector. The system in place here is a monitoring device similar to what you've described. In the past, it was our practice to introduce a marked bottle, damaged enough to break and verify that the established pattern around it was rejected, based on visual evidence and the machine's log.

However, our recently acquired parent company has made the totally reasonable assertion that perhaps introducing broken glass is not the best practice in avoiding it....

We do keep a #100 mesh screen for checking the bottles around the reject, but as you say, how does one check that? Unless we slowed down the filler dramatically and waited (perhaps days...) for a bottle to break, there's no way. 



lorlandini

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Posted 14 January 2022 - 06:14 PM

I have worked in the beverage industry since 1988.  The fact is bottles will explode when counter-pressuring the bottle.   Besides culling bottles before and after the exploded bottle, I always like to do a visual inspection of the sealing rubber on the filler valve that the contained the exploded bottle.   Glass shards can and have become stuck in the sealing rubber and unless you inspect and/or replace, you have the potential of introducing the glass shards to additional bottles during the filling process.

 

If you have a high speed line and and encountering frequent explosions, I would definitely start a conversation with your glass supplier.

 

Leo






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