The Need
North American leader in integrated packaging solutions, has a bottling plant where the capping process is very critical. Manual process were used for calibration and monitoring of the bottle capping process. This was resulting in inefficiencies as well as with high volume of QA rejects.
Impacts Delivered
- More than 70% reduction in QA rejects for the wine bottle capping process.
- 40% lower TCO by leveraging Gadgeon IIoT solution platform – Delpheon.
- The solution enhanced the accuracy and efficiency of the capper head calibration.
Our Solution
Capping Process Monitoring and Management
- The Solution was developed using Gadgeon Industrial IoT Platform – Delpheon.
- Designed and developed a custom Dummy Bottle with 9 force sensors, an RFID reader along with Wi-Fi interface to capture data from the production line.
- The Dummy Bottle enables monitoring of performance of the capper-heads while it is running at commercial speed.
- The dashboard provides information to the line owner about each head on the capping turret in near real-time.
The calibration process for the capper head is Digitized
- The solution enabled Mechanics in setting up their capper-heads accurately and efficiently, guaranteeing its peak performance.
Tools & Technologies
- Hadware and firmware design for the dummy bottles
- Sensor integration – Force sensors, position sensors, accelerometers, RFID
- Wi-Fi Interface for data transfer
- Web based GUI for Calibration process digitization
- Data analytics and Dashboarding using Delpheon Low-code platform.
- Real-time notification – SMS / Email
Block Diagram – Capping Process Monitoring
Digitization of Capper Head Calibration Process
