Agr’s new Pilot Core™ automated material distribution measurement and blowmolder process control system offers a cost-effective, entry-level solution to ensure that all production bottles have your required quality and performance attributes. Geared toward lines producing PET bottles with less complex geometries at lower speeds, the Pilot Core system is a prime solution for 24/7 process control.
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This critical process tool mounts inside the blowmolder and automatically controls the production process based on continuous monitoring of material distribution on every bottle. The comprehensive and precise thickness measurement provided by the Pilot Core system is key to accomplishing proper process control – without operator intervention. The automated system monitors operation 100% of the time for the slightest changes in material distribution and continuously adjusts the blowmolder to keep the process on track. This is a level of control that is unattainable by human operators.
The Pilot Core system provides direct measurements over the entire sidewall of the bottle, regardless of shape or material thickness. The evenly spaced measurement points offer a unique profile-style approach to monitor material distribution and eliminate measurement location issues. The sensors are in a hermetically sealed, compact measurement unit that fits in most blowmolders. The symmetrical orientation of the sensors effectively tracks and monitors any shifts in material distribution at a high-speed sampling rate. Based on Agr’s IR absorption method, the highly accurate and repeatable measurements of PET bottles are performed at production speeds and provide immediate indication of any distribution issues.
Any change in distribution can be identified from source to destination. With this type of feedback, the Pilot Core system provides precise process control and monitors performance factors on a per bottle basis while eliminating the variation in environment, material or operator experience. With its combination of hardware and sophisticated algorithms, the Pilot Core system continually analyzes the material distribution changes and automatically adjusts critical blowmolder settings to maintain the process at optimum levels.
In the management of the production process, the Pilot Core system provides:
• Quick setup and job changes
• Continuous, multi-point feedback
• Real-time data communication
• On-going process reports with visual indicators
• Mold and spindle data correlation
• Accelerated blowmolder troubleshooting
The comprehensive measurement approach offers a complete understanding of the bottle, and through continuous monitoring and adjustment, maintains the blowing process at optimum levels. The optimization keeps the process efficient and cost-effective, providing real savings in:
• Material
• Productivity
• Quality
• Reduced scrap
• Overall cost
• Energy
• Downtime
• Labor
The use of the Pilot Core system will help you control your blowmolding process in a way that best suits your production goals such as maximizing line efficiency, producing lighter weight bottles, allowing for higher rPET content and supporting corporate sustainability goals.
Picture: Agr
