J9475 Consumer Product Filling - Capping - Packaging System

The Consumer Product Filling - Capping - Packaging System is an advanced, automated solution designed to process empty, unlabeled bottles through a comprehensive sequence of operations: labeling, filling, capping, carton loading, case packing, and palletizing. Engineered to operate at a gross production rate of 160 bottles per minute (bpm), the system integrates cutting-edge robotics, conveyors, and vision technology to ensure efficiency and precision. The process begins with operators loading empty bottles into a Farason Bottle Sorting and Feeding Machine hopper. Bottles are sorted, conveyed, and oriented via an AC-driven Vision Conveyor and ABB IRB-360 Delta Robot, which places them into staging nests. A second ABB IRB-1200 Six-Axis Robot then transfers bottles (6-Up) for air rinsing and placement onto a dual-sided flat belt conveyor. To optimize throughput, a duplicate Farason sorting system is included. Downstream, bottles are labeled using two dedicated Inline Nita Labeling Machines—one for each product variant—followed by vision inspection for label accuracy. Bottles then enter an AB Servo-driven timing screw for spacing and are picked (5-Up) by ABB IRB-910SC SCARA Robots and placed onto Magnemotion vehicles. These vehicles transport bottles through puck charging, filling (via dual independent cells with five fill heads each), and capping operations, accommodating both product variants. Caps are applied using AB Servo torque heads and custom feeder assemblies, with additional Dose cups added by another SCARA robot. Post-filling, bottles pass through Axon Aurora 4.0 SS sleever machines for sleeve application, followed by heat/steam shrinking and drying. A Domino laser marks codes onto labels, and bottles are inspected before being carton-loaded by an ABB IRB-1200 Six-Axis Robot into a Douglas Vectra Cartoner. Cartons proceed to a dual-robot Case Packer Loading Machine and a Douglas CpONE Case Packer. Cases are printed, Cognex-inspected, and palletized by an ABB IRB-460 robot, with pallets stretch-wrapped by a Lantech QL Series machine. Completed products exit the machine on an outfeed conveyor for operator removal.