ErgoBloc L - PETnologycleaning tasks 6 ｜KRONES ErgoBloc L The components: blow moulder −Output per blowing station: up to 2,300 containers per hour −Electromagnetic stretching

ErgoBloc L The wet section block which performs much and requires very little

2 ｜KRONES ErgoBloc L

A lot of machinery in just a small space

When it comes to its output per square metre, the ErgoBloc L plays in its own league. The wet section block has an output of up to 81,000 containers/h and requires 70 percent less space than conventional lines. At a glance − Functions: Blow moulding, labelling, filling and capping − Output: up to 81,000 containers per hour − Processing range: Carbonated and non-carbonated beverages Cylindrical and square PET containers Standard and lightweight containers Volume of 0.25 to 3.0 litres Self-adhesive labels and reel-fed plastic labels Flat caps and sports caps

L = Liquid


What the ErgoBloc L does best, is: Save, save, save!

These five examples show where the ErgoBloc L is saving:

1. Area − Up to 30 % less area used than with conventional blow

moulder filler blocks − Up to 70 % less area used than with lines consisting of

individual machines and conveyors

2. Malfunction risks − Omission of conveyors and buffer sections − Perfectly interlocked processes

3. Working time − Operation of the entire block with only one operator − Designed as a multi-format line with especially short change-

over times − Short ramp-up phase

4. Energy and media − No rinser required − No conveyors and buffers − No container dryer required in front of of the labeller − Recycling systems for energy and blowing air − Use of energy-efficient components such as servo motors electromagnetic stretching system

5. PET material − Exact configuration of all process steps for lightweight

preforms and containers


Method of operation – step by step

1. Feeding of the preforms

2. Heating of the preforms

3. Blow moulding of the containers

6. Cooling of the container base with water*

5. Labelling 8. Capping

7. Filling

4. Cooling of the container base with air

* only required with CSD


The components: Preform feed unit

− Gentle preform conveying − Automatic troubleshooting − Quick and infinitely variable adjustment to any preform type

via handwheel and register − Easy access to individual components for maintenance and

cleaning tasks


The components: blow moulder

− Output per blowing station: up to 2,300 containers per hour − Electromagnetic stretching system without compressed air

consumption − Integrated quick-change system for moulds − Energy-efficient infrared linear oven with ceramic reflectors − Actively controlled transfer grippers − Extremely reduced dead space volume Hygiene and cleaning − Hygienic design − Light coating in the interior for immediate detection of dirt


The components: modular labeller

− Labelling station with gap detection No machine stop in case of missing PET containers Continuous operation at rated speed

− Lubrication-free drive − Hygienic design without table top

Why label first and fill afterwards? − Full bottles can have varying internal pressures. − These variations can impact the labelling result. Solution: The ErgoBloc L … − labels the bottles before filling them. − pressurises the empty bottles with filtered air.

Result: Identical conditions for every bottle Excellent label position


The components: filler

− Swirl insert in the valve for a low-foam filling process which is gentle on the product

− Flow meter for precise fill levels − Filling speed that can be adjusted to the product − Hygienic design without table top − Optional: Clean room


The components: drive technology

− Consistent use of servo drives energy-efficient low wear reliable

SJC – Servo Joint Control Single machines or block mode? Both is possible: Because with the Servo Joint Control, you can electronically decouple the blow moulder, labeller and filler from the block. − Automatic decoupling during malfunction − Automatic synchronisation during restart − Manual decoupling of individual machines for efficient change-

over processes => SJC makes it possible: The ErgoBloc L thinks on its own!


− Intuitive operation with task-oriented menus − Uniform look and feel at all three individual machine HMIs Only one operator required for the entire block

The components: HMI


The components: transfer grippers

− Actively controlled transfer grippers − Container conveyance via neck handling Quick and extremely precise preform and bottle transfer Smallest possible contact area between the material and the

machine Gentle conveyance also for light-weight containers Reduction of handling parts No PET abrasion during the transfer


Option: retrofitting in record time with LineXpress

Function: The LineXpress … − coordinates all steps which are required for

the change-over. − allows a fully-automatic performance of

essential processes − leads the operator quickly through the

process and without any faults. − enables several process steps

simultaneously instead of in succession. Result: The ErgoBloc L … − can be adjusted to a new product in 10

minutes. − can be changed to different types in 30

minutes. − increases the line efficiency by up to 20

percent.

LineXpress

Production of the batch

Emptying of the line

Start of the new type

On-the-fly change-over

for the supply system

Retrofitting of the

machines

Automatic initiation of the product change-over


Benefits to you

Large output in a small area Even though it processes up to 81,000 containers per hour, the ErgoBloc L requires up to 70 percent less space than a line consisting of individual machines. This way, you can save hundreds of square metres of hall surface. Gentle treatment for PET containers The active transfer grippers only touch the preforms and bottles in their neck area. This makes the contact area between the material and the machines as small as possible and minimises the risk of damage. Energy saving From the servo drives to the electromagnetic and compressed-air free stretching systems: The topic energy efficiency goes all the way through the block just like a red thread.

Trouble-free continuous operation Full power with no breaks: The labelling module automatically detects bottle gaps and does not apply glue or labels in this case so malfunctions through missing bottles are no topic at all. Four process steps – one operator With the ErgoBloc L, the entire process from stretch blow moulding right through to the capping of the containers can be looked after by just one person. The compact design without conveyor sections also keeps the transport distances short and offers an easy overview over the entire line.


Everything from a single source

Training sessions at the KRONES Academy – trained personnel increases your line efficiency The versatile training offer ranges from operation, servicing and maintenance to management training. We will gladly also establish your individual training programme. KIC KRONES adhesives – the all-rounder for a strong grip Regardless if PET or glass, plastic or paper, labels or packagings – at KIC KRONES, you will find your ideal adhesives for a high-quality product presentation. KIC KRONES cleaning agents make your machine shine Only if the production environment is immaculate, can your product be brilliant. KIC KRONES provides you with the optimum cleaning agents and disinfectants for each individual production step.

Lubricants from KIC KRONES for every production step Whether for gears, chains or central lubrication systems – our greases and oils are true all-round talents. They can reach every lubrication point, protect your line and ensure gentle treatment for your products thanks to their food-grade quality. KRONES Lifecycle Service – partner for performance Also after having purchased a new machine, KRONES will take care of your line; the LCS experts are always ready to consult you and translate your goals and wishes into optimal LCS solutions. EVOGUARD – excellent valve technology all along the line The valve series of EVOGUARD comprises a modular system with hygienic and aseptic components which contributes to every point of the production line with increased performance and which has the perfect solution for every process step.

We do more.

Digitalisation Process technology

Bottling and packaging equipment

Intralogistics Lifecycle Service

Documents

ErgoBloc L - PETnologycleaning tasks 6 ｜KRONES ErgoBloc L The components: blow moulder −Output per blowing station: up to 2,300 containers per hour −Electromagnetic stretching