U.S. patent application number 13/571919 was filed with the patent office on 2013-04-04 for efficient production line for aerosol cans.
This patent application is currently assigned to MALL & HERLAN GMBH. The applicant listed for this patent is Johannes Linden, Herrn Bernd Ullmann. Invention is credited to Johannes Linden, Herrn Bernd Ullmann.
Application Number | 20130084148 13/571919 |
Document ID | / |
Family ID | 46880567 |
Filed Date | 2013-04-04 |
United States Patent
Application |
20130084148 |
Kind Code |
A1 |
Linden; Johannes ; et
al. |
April 4, 2013 |
EFFICIENT PRODUCTION LINE FOR AEROSOL CANS
Abstract
A production line with processing stations processing products
with a production speed in products per unit time, the production
line comprising a temporarily discontinuously operating processing
station; a production line section connected upstream of the
temporarily discontinuously operating processing station; a
production line section connected downstream from the temporarily
discontinuously operating processing station; a first product
buffer arranged between the upstream production line section and
the temporarily discontinuously operating processing station; and a
second product buffer arranged between the temporarily
discontinuously operating processing station and the downstream
production line section.
Inventors: |
Linden; Johannes;
(Waldbronn, DE) ; Ullmann; Herrn Bernd; (Pfinztal,
DE) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Linden; Johannes
Ullmann; Herrn Bernd |
Waldbronn
Pfinztal |
|
DE
DE |
|
|
Assignee: |
MALL & HERLAN GMBH
Pfinztal
DE
|
Family ID: |
46880567 |
Appl. No.: |
13/571919 |
Filed: |
August 10, 2012 |
Current U.S.
Class: |
414/222.02 ;
414/806 |
Current CPC
Class: |
B21D 51/16 20130101;
Y02P 90/20 20151101; B65B 57/04 20130101; Y02P 90/02 20151101; G05B
2219/31078 20130101; G05B 2219/32265 20130101; G05B 19/41865
20130101; Y02P 90/083 20151101 |
Class at
Publication: |
414/222.02 ;
414/806 |
International
Class: |
B65B 57/04 20060101
B65B057/04 |
Foreign Application Data
Date |
Code |
Application Number |
Aug 10, 2011 |
DE |
10 2011 080 769.1 |
Claims
1. A production line with processing stations processing products
with a production speed in products per unit time, the production
line comprising: a temporarily discontinuously operating processing
station; a production line section connected upstream of the
temporarily discontinuously operating processing station; a
production line section connected downstream from the temporarily
discontinuously operating processing station; a first product
buffer arranged between the upstream production line section and
the temporarily discontinuously operating processing station; and a
second product buffer arranged between the temporarily
discontinuously operating processing station and the downstream
production line section, wherein the production line is connected
with a control controlling the production line, wherein the
temporarily discontinuously operating processing station operates
with an increased production speed that is increased relative to
the upstream production line section and the downstream production
line section after a production interruption of the temporarily
discontinuously operating processing station until the initially
filled first product buffer is emptied to a predetermined level
and/or the initially emptied second product buffer is filled to a
predetermined level, and wherein the upstream production line
section and the downstream production line section can continue to
produce in case of a production interruption of the temporarily
discontinuously operating processing station until the initially
emptied first product buffer is filled to a predetermined level
and/or the initially filled second product buffer is emptied to a
predetermined level.
2. The production line according to claim 1, wherein the
temporarily discontinuously operating processing station is a deco
station for decorating a product with a respectively replaceable
decoration, wherein replacing the decoration requires a retrofit
time which causes a respective production interruption of the deco
station, and wherein the production buffers have a buffer capacity
which is respectively adjusted to the production speed of the
respective upstream production line section and the respective
downstream production line section, so that a filling time provided
at this production speed for filling the first product buffer
and/or an emptying time provided for emptying the second product
buffer is greater or equal to the retrofit time.
3. The production line according to claim 1, wherein the control
controls the upstream production line section and the downstream
production line section so that the upstream production line
section and the downstream production line section operate at their
maximum possible production speeds if the number of products to be
processed in a batch is greater or equal to the product of the
emptying time of the first product buffer related to this maximum
production speed and the maximum possible production speed of the
upstream production line section, and if this condition does not
apply, the upstream production line section and the downstream
production line section operate with a production speed that is
reduced relative to their maximum possible production speed.
4. The production line according to claim 1, wherein the upstream
production line section and the downstream production line section
are configured for a maximum production speed of 200 products per
minute.
5. The production line according to claim 1, wherein the upstream
production line section and the downstream production line section
are configured for a maximum production speed of 250 products per
minute.
6. The production line according to claim 1, wherein the control
controls the upstream production line section and the downstream
production line section so that the production speed of the
upstream production line section and the production speed of the
downstream production line section are equal.
7. The production line according to claim 1, wherein the upstream
production line section includes an extrusion press and the
downstream production line section includes a folding station.
8. The production line according to claim 1, wherein the upstream
production line section includes a drawing device and/or a
stretching device or a combined drawing--stretching device.
9. A method for operating a production line including a temporarily
discontinuously operating processing station, a production line
section connected upstream of the temporarily discontinuously
operating processing station, a production line section connected
downstream from the temporarily discontinuously operating
processing station, a first product buffer arranged between the
upstream production line section and the temporarily
discontinuously operating processing station, and a second product
buffer arranged between the temporarily discontinuously operating
processing station and the downstream production line section,
comprising: operating the temporarily discontinuously operating
processing station with an increased production speed that is
increased relative to the upstream production line section and the
downstream production line section after a production interruption
of the temporarily discontinuously operating processing station
until the initially filled first product buffer is emptied to a
predetermined level and/or the initially emptied second product
buffer is filled to a predetermined level, wherein the upstream
production line section and the downstream production line section
can continue to produce in case of a production interruption of the
temporarily discontinuously operating processing station until the
initially emptied first product buffer is filled to a predetermined
level and/or the initially filled second product buffer is emptied
to a predetermined level.
10. The method according to claim 9, further comprising:
retrofitting the temporarily discontinuously operating processing
station, wherein the temporarily discontinuously operating
processing station is a deco station for decorating a product with
a respectively replaceable decoration, wherein replacing the
decoration requires a retrofit time which causes a respective
production interruption of the deco station, and wherein the
production buffers have a buffer capacity which is respectively
adjusted to the production speed of the respective upstream
production line section and the respective downstream production
line section, so that a filling time provided at this production
speed for filling the first product buffer and/or an emptying time
provided for emptying the second product buffer is greater or equal
to the retrofit time.
11. The method according to claim 9, further comprising: operating
the upstream production line section and the downstream production
line section at their maximum possible production speeds if the
number of products to be processed in a batch is greater or equal
to the product of the emptying time of the first product buffer
related to this maximum production speed and the maximum possible
production speed of the upstream production line section, and if
this condition does not apply, reducing the production speed of the
upstream production line section and the downstream production line
section relative to their maximum possible production speed.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority under 35 USC .sctn.119 to
German Patent Application No. 10 2011 080 769.1 filed on Aug. 10,
2012, which application is hereby incorporated by reference.
TECHNICAL FIELD
[0002] The invention relates to a production line with processing
stations which process products per unit time with a production
speed, wherein the production line includes a processing station
operating discontinuously from time to time, a production line
section arranged upstream of the processing station and a
production line section arranged downstream of the processing
station.
BACKGROUND OF THE INVENTION
[0003] Production lines of the type recited supra are known in the
art and are being used for example when producing and/or processing
containers like aerosol cans, beverage cans or tubes.
[0004] Typical production speeds of production lines of this type
are between 50 and 2500 containers per minute (subsequently
designated as cpm), wherein production speeds of greater than 500
cpm are typically used during mass production of beverage cans,
production speeds of less than 100 cpm are used in the production
of special containers like aluminum tubes. Production lines for
producing aerosol cans are configured for a production speed
between 100 cpm and 500 cpm, in particular between 150 cpm and 250
cpm.
[0005] The containers to be produced are typically combined in
so-called batches, wherein a batch defines a number of containers
which are processed by a discontinuously operating processing
station between two retrofits of the processing station. In aerosol
can production, the batch size is typically 10000 to 1000000
containers.
[0006] For the duration of a retrofit wherein the retrofit is for
example a decor change of a decoration station, besides the
processing station itself standing still that needs to be
retrofitted, also the upstream or downstream production line
section of the processing station stands still.
[0007] In order to compensate the productivity reduction caused by
a standstill of this type, a processing station that operates
discontinuously from time to time and the upstream or downstream
production line section of the processing station are configured
for a production speed which is typically significantly higher than
a production speed of a production line without retrofit
requirement.
SUMMARY OF THE INVENTION
[0008] The invention is based on the finding that the cost for a
production line is disproportionally high in the prior art, since
the entire production line is configured for a higher production
speed.
[0009] It is the object of the present invention to provide a
production line with a processing station that operates
discontinuously from time to time, wherein the production line
achieves high productivity with lowest possible complexity. This
object is achieved by a production line in that a first product
buffer is arranged between the upstream production line section and
the processing station that temporarily operates in a discontinuous
manner and a second product buffer is provided between the
processing station that temporarily operates in a discontinuous
manner and the downstream production line section and the
production line is connected with a control which controls the
production line so that the temporarily discontinuously operating
processing station after a production interruption of the
processing station operates with increased production speed
relative to the upstream and the downstream production line section
until the initially filled first product buffer is depleted down to
a predetermined amount and/or the initially depleted second product
buffer is filled to a predetermined amount.
[0010] In the production line according to the invention, the
upstream production line section and the downstream production line
section in case of a production interruption of the temporarily
discontinuously operating processing station can continue to
produce until the initially depleted first product buffer is filled
to a predetermined amount and/or the initially filled second
production buffer is depleted to a predetermined amount, so that
the upstream production line section and the downstream production
line section can have a lower production speed than comparable
prior art production line sections without the production speed of
the entire production line being lower.
[0011] The solution according to the invention includes the finding
that prior production improving measures are directed to increasing
production speed in itself. It was also found that a higher
production speed comes with a higher scrap rate which in turn
causes an effective productivity reduction. A significant quality
increase of the products produced is achieved in that the maximum
production speed is only increased in one processing station, thus
the processing station temporarily operating in a discontinuous
manner and the maximum production speeds of the production line
sections that are connected upstream or downstream are limited.
[0012] Discontinuous manner in this context means that a processing
station operating in a discontinuous manner temporarily does
temporarily not operate with its actual production speed but that
its production is temporarily interrupted, wherein the interruption
does not have to coincide with an abrupt change of the production
speed, for example between standstill (for a production
interruption) and increased production speed. A discontinuous
operating mode rather means that a transition of the production
speed from standstill to another production speed can be provided
without speed leaps.
[0013] The solution according to the invention can be supplemented
with additional advantageous embodiments. Some of the embodiments
are subsequently described.
[0014] In a particularly preferred embodiment, the temporarily
discontinuously operating processing station is a deco station for
decorating a product with a respectively replaceable decoration.
Replacing the decoration requires retrofit time which causes a
respective production interruption of the deco station. The
production buffers have a buffer capacity which are respectively
adjusted to the production speed of the upstream production line
section or the downstream production line section so that a filling
time used with this production speed for filling the first product
buffer and/or an emptying time used for emptying the second product
buffer is greater than or equal to the retrofit time.
[0015] In order to facilitate an optimum loading of the production
line, the control can control the upstream production line section
and the downstream production line section so that the upstream
production line section and the downstream production line section
operate with their maximum possible production speed as long as the
number of products to be processed in a batch is greater or equal
to the product of the emptying time of the first product buffer
related to this maximum production speed and the maximum possible
production speed of the upstream production line section.
[0016] As long as the number of the products to be processed in a
batch is less than the product of the emptying time of the first
product buffer related to the maximum production speed of the
upstream production line section and the downstream production line
section and the maximum possible production speed of the upstream
production line section, the control can cause the upstream
production line section and the downstream production line section
to operate with a reduced production speed relative to its maximum
possible production speed. This facilitates a reliable production
in particular for small batch sizes.
[0017] In order to be configured in an optimum manner for the
requirements of aerosol can production, the upstream production
line section and the downstream production line section in an
advantageous embodiment are configured for a maximum production
speed of 200 products per minute. In an alternative embodiment, the
temporarily discontinuously operating processing station is
configured for a maximum production speed of 250 products per
minute. In another advantageous embodiment, the upstream production
line section and the downstream production line section are
configured for a maximum production speed of 250 products per
minute.
[0018] For a particularly advantageous operation of the production
line, the maximum production speed of the upstream production line
section and of the downstream production line section can be higher
than 150 products per minute and lower than 300 products per
minute. In order to facilitate particularly uniform filling and
emptying of the product buffers, the control can control the
upstream production line and the downstream production line so that
the production speed of the upstream production line and the
production speed of the downstream production line are
identical.
[0019] In a particularly advantageous embodiment, the upstream
production line section includes an extrusion press and the
downstream production line section includes a fold over station.
Since stations of this type are very expensive, limiting their
maximum production speed is particularly advantageous for the cost
of the entire production line.
[0020] The deco station can include a coating unit, a decoration
unit, a lacquering unit and the associated drying ovens. In an
alternative embodiment, the temporarily discontinuously operating
processing station is configured as a decoration drying oven.
[0021] In another advantageous embodiment, the upstream production
line section includes a drawing device and/or a stretching device.
The downstream production line section can include a combined
drawing-stretching device. In a particularly advantageous
embodiment, the drawing device is a "cupper". The stretching device
can be a "body maker".
[0022] The object of the invention is achieved through a method for
operating a production line, wherein the production line includes a
temporarily discontinuously operating processing station, a
production line section connected upstream of the temporarily
discontinuously operating processing station, a production line
section connected downstream of the temporarily discontinuously
operating processing station, a first product buffer arranged
between the upstream production line section and the temporarily
discontinuously operating processing station and a second product
buffer arranged between the temporarily discontinuously operating
processing station and the downstream production line section.
[0023] The method provides that the temporarily discontinuously
operating processing station is operated with an increased
production speed relative to the upstream and the downstream
production line section after a production interruption of the
processing station until the initially filled first product buffer
is emptied to a predetermined amount and/or the initially emptied
second product buffer is filled to a predetermined amount.
[0024] The upstream production line section and the downstream
production line section can continue to produce in case of a
production interruption of the temporarily discontinuously
operating processing station until the initially emptied first
product buffer is filled to a predetermined amount and/or until the
initially filled second product buffer is depleted to a
predetermined amount.
[0025] In a particularly advantageous embodiment, the method
provides retrofitting the temporarily discontinuously operating
processing station, wherein the processing station is a deco
station for decorating a product with a respectively replaceable
decoration and the retrofitting means a replacement of the
decoration with a retrofit time which causes a respective
production interruption of the deco station. The production buffers
have a buffer capacity which is respectively adapted to the
production speed of the upstream production line section and/or of
the downstream production line section so that a filling time that
is used at this production speed for filling the first product
buffer and an emptying time that is used at that production speed
for emptying the second product buffer is great than or equal to
the retrofit time.
[0026] In an advantageous embodiment, the upstream production line
section and the downstream production line section are operated
with their maximum production speed as long as the number of the
products to be processed in a batch is greater than or equal to the
product of the emptying time of the first buffer related to this
maximum production speed and the maximum possible production speed
of the upstream production line section.
[0027] In a particularly advantageous embodiment, the production
speed of the upstream production line section, and of the
downstream production line section, are reduced with respect to
their maximum possible production speed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] Subsequently the invention is described with reference to
embodiments illustrated in drawing figures. The different features
in the drawing figures like in the embodiments described supra are
randomly combinable with one another, wherein:
[0029] FIG. 1 illustrates a schematic depiction of an exemplary
embodiment of a production line according to the invention in a
stationary production condition directly before a retrofit
starts;
[0030] FIG. 2 illustrates a schematic depiction of an exemplary
embodiment of the production line of FIG. 1 in a production
condition directly after a beginning of a retrofit;
[0031] FIG. 3 illustrates a schematic illustration of an exemplary
embodiment of the production line according to the invention
according to FIG. 1 in a production condition during retrofit;
[0032] FIG. 4 illustrates a schematic depiction of an exemplary
embodiment of the production line according to the invention
according to FIG. 1 in a production condition directly before an
end of the retrofit;
[0033] FIG. 5 illustrates a schematic depiction of an exemplary
configuration of the production line according to the invention
according to FIG. 1 in a production condition directly after the
end of the retrofit;
[0034] FIG. 6 illustrates a schematic depiction of an exemplary
embodiment of the production line according to the invention
according to FIG. 1 in a production condition substantially after
the end of the retrofit;
[0035] FIG. 7 illustrates a schematic depiction of an exemplary
embodiment of the production line according to the invention
according to FIG. 1 in a production condition directly before
reaching a stationary production condition;
[0036] FIG. 8 illustrates an exemplary embodiment of the production
line according to the invention according to FIG. 1 in a stationary
production condition; and
[0037] FIG. 9 is a chart that illustrates the required difference
in production speeds according to the invention.
DETAILED DESCRIPTION
[0038] An assembly line 100 in FIGS. 1 through 8 includes a
temporarily discontinuously operating processing station 1 with a
production speed v1. The temporarily discontinuously operating
processing station 1 has a production line section 2 connected
upstream and a production line section 3 connected downstream. The
production line section 2 operates with a production speed v2, the
production line section 3 operates with a production speed v3.
[0039] Between the upstream production line section 2 and the
temporarily discontinuously operating processing station 1, a first
product buffer 4 with a buffer level p4 is arranged between the
temporarily discontinuously operating processing station 1 and the
downstream production line section 3 a second product buffer 5 with
a buffer level p5 is arranged. A transfer of the products to be
processed from the first product buffer 4 to the processing station
1 is provided with a transfer speed v6, a transfer of the process
products from the processing station 1 to the product buffer 4 is
provided with a transfer speed v7. The change of the buffer level
p4 per minute is indicated as v4, the change of the buffer level p5
per minute is designated as v5. A positive prefix of v4 or v5
indicates an increasing buffer level, a negative prefix indicates a
decreasing buffer level.
[0040] With reference to the configuration of the production lines
100 described in FIGS. 1 through 6, a retrofit time T of 30 minutes
is defined. The upstream production line section 2 and the
downstream production line section 3 are configured for a maximum
production speed of 200 cpm, the temporarily discontinuously
operating processing station is configured for a maximum production
speed of 250 cpm. The upstream production line section 2 and the
downstream production line section 3 are continuously operated with
their maximum production speeds of 200 cpm.
[0041] During a retrofit of the temporarily discontinuously
operating processing station 1, the upstream production line
section 2 and the downstream production line section 3 continue to
operate with their maximum production speed of 200 cpm, thus they
process a number of 6,000 containers respectively during the
retrofit time of 30 minutes (200 cpm.times.30 min.). In order to
maintain a continuous production, therefore, a buffer size of 6,000
containers is required for the product buffers 4 and 5. After the
retrofit is completed, the product buffer 4 has grown to 6,000
containers, the product buffer 5 is emptied.
[0042] The number of 6,000 containers corresponds to the amount to
which the product buffer 4 or the product buffer 5 are filled, the
number of 0 containers corresponds to the predetermined amount to
which the product buffer 4 or the product buffer 5 are depleted.
The buffer capacity corresponds to 6,000 containers.
[0043] For the retrofit required for the next batch, the buffer
level p5 has to be reduced to its original amount of p5=6,000, the
buffer level p4 has to be reduced to its original amount of p4=20.
Since the temporarily discontinuously operating processing station
1 is configured for a maximum production speed of 250 cpm and thus
exceeds the production speed of the upstream production line
section 2 or the downstream production line section 3 by 3 to 50
cpm, this yields a time frame of 120 minutes (6,000/(250 cpm-50
cpm)) for completely loading the product buffer 5 or unloading the
product buffer 4.
[0044] In the time frame of 120 minutes, the upstream production
line section 2 and the downstream production line section 3 of
24,000 containers (120 minutes.times.200 cpm) is run through. This
number of 24,000 containers thus represents a maximum batch size B
up to which a continuous operation of the upstream production line
section 2 and the downstream production line section 3 is
feasible.
[0045] These definitions refer to the instant embodiment and do not
represent a general limitation. Furthermore, it is clear to a
person skilled in the art that the defined values are not
maintained mathematically exact in production reality, they rather
are subject to normal technical variations and other production
technique considerations.
[0046] FIG. 1 illustrates the production line in a stationary
production condition, the stationary mode. The entire production
line 100 operates with a uniform production speed of 200 cpm
(v1=v2=v3=v6=v7=200 cpm). The product buffer 4 is in empty
condition (p4=0), whereas 6,000 containers are included by the
second product buffer 5 (p5=6,000).
[0047] FIGS. 2 through 4 illustrate the production line during
retrofit, the retrofit mode. During this time, the temporarily
discontinuously operating processing station 1 stands still (v1=0
cpm), a transfer of products from the first product buffer 4 to the
processing station 1 does not occur and a transfer of products from
the processing station 1 to the product buffer 4, this means the
transfer speed v7 or v6 are 0 cpm. The upstream production line
section 2 and the downstream production line section 3 operate with
a production speed of 200 cpm, wherein these production line
sections process a number of 6,000 containers respectively (200
cpm.times.30 minutes) during the retrofit time period. This number
determines the buffer requirement for maintaining a continuous
production.
[0048] When the retrofit mode starts (FIG. 2), the buffer level p4
of the product buffer 4 increases at 200 cpm, the buffer level p5
of the product buffer 5 decreases with 200 cpm. After a retrofit
time of 5 minutes, the product buffer 4 includes 1,000 containers
(p4=1,000), the product buffer 5 has a level of 5,000 containers
(p5=5,000).
[0049] During the retrofit mode (FIG. 3) after 15 minutes, the
product buffer 4 includes 3,000 containers (p4=3,000), the product
buffer 5 also has a level of 3,000 containers (p5=3,000).
[0050] Directly before an end of the retrofit mode (FIG. 4), after
28 minutes, the product buffer 4 includes 5,600 containers
(p4=5,600), the product buffer 5 has a level of 400 containers
(p5=400).
[0051] At an end of the retrofit mode after 30 minutes, the product
buffer 4 includes 6,000 containers (p4=6,000), the product buffer 5
is empty (p5=0).
[0052] FIGS. 5 through 7 illustrate the production line during
filling the product buffer 4, the refill mode. In refill mode which
comes directly after the retrofit mode, the temporarily
discontinuously operating processing station 1 operates with an
increased production speed (v1=250 cpm). A transfer of products
from the first product buffer 4 to the processing station 1 and a
transfer of product from the processing station 1 to the product
buffer 4 is accordingly provided respectively with an increased
transfer speed, this means the transfer speeds v7 or v6 are 250 cpm
respectively. The upstream production line section 2 and the
downstream production line section 3 continue to operate with the
production speed of 200 cpm. For the product buffer, this yields a
net of -50 cpm (v2-v6), this means the buffer level p4 decreases,
the buffer level p5 increases by 50 cpm (v7-v3), this means the
buffer level p4 increases. Since the buffer level p5 has to be
reduced to its original amount of p5=6,000, this yields a duration
of the filling mode of 120 minutes (6,000/50 cpm).
[0053] Five minutes after the refill mode begins (FIG. 5), the
product buffer 5 includes 250 containers (p5=250), the product
buffer 4 has a level of 5,750 containers (p4=5,750).
[0054] During the refill mode (FIG. 6), this means 60 minutes after
the refill mode begins, the product buffer 5 includes 3,000
containers (p5=3,000), the product buffer 4 also includes a level
of 3,000 containers (p4=3,000).
[0055] Directly before an end of the refill mode (FIG. 7), this
means 110 minutes after the refill mode begins, the product buffer
5 includes 5,500 containers (p5=5,500), the product buffer 4 has a
level of 500 containers (p4=500).
[0056] When the refill mode ends after 120 minutes, the product
buffer 5 is completely filled (p5=6,000), the product buffer 4 does
not include any more containers (p4=0).
[0057] FIG. 8 in turn illustrates a production line 100 in a
stationary production condition which follows directly after the
refill mode described with reference to FIGS. 5 through 7. The
entire production line 100 operates with uniform production speeds
of 200 cpm (v1=v2=v3=v6=v7=200 cpm). The product buffer 4 is in
empty condition (p4=0), whereas 6,000 containers are included in
the second product buffer 5 (p5=6,000).
[0058] The subsequent tables summarize parameters for the preceding
embodiments.
TABLE-US-00001 Reference Numeral/Production Stationary Mode
Retrofit Mode Refill Mode Condition (FIG. 1, FIG. 8) (FIG. 2-FIG.
4) (FIG. 5-FIG. 7) p4 (c = Container) 0 0-6000 6000-0 v4 (cpm) 0
200 -50 p5 (c = Container) 600 6000-0 0-6000 v5 (cpm) 0 -200 50 v6
(cpm) 200 0 250 v7 (cpm) 200 0 250 v1 (cpm) 200 0 250 v2 (cpm) 200
200 200 v3 (cpm) 200 200 200
[0059] In the embodiment described supra, 24,000 containers (120
minutes.times.200 cpm) are respectively processed by the upstream
production line section 2 and the downstream production line
section 3 within 120 minutes which corresponds to the time period
for completely loading the product buffer 5 or unloading the
product buffer 4. This means that the entire production line
processes 24,000 containers--one batch--in these 120 minutes. The
number of 24,000 containers which represents a typical batch size
during aerosol production by the same token represents a minimum
batch size up to which a continuous operation of the upstream
production line section 2 and the downstream production line
section 3 is possible at its maximum production speed of 200
cpm.
[0060] The design parameters used for the preceding configuration
can be determined in a general manner so that they go beyond the
particular embodiment.
[0061] Reciting another embodiment, depending on the batch size to
be processed and the retrofit time, the upstream production line
section 2 and the downstream production line section 3, for
example, can have a maximum production speed of 150 cpm and the
temporarily discontinuously operating processing station 1 can have
an increased production speed of 200 cpm (150/200 operating mode).
Additional operating modes are for example 150/180, 250/300 or
250/350.
[0062] FIG. 9 illustrates the required difference in production
speeds, this means the amount by which the production speed of the
temporarily discontinuously operating processing station after a
production interruption of this processing station has to exceed
the production speed of the upstream and downstream production line
sections in order to facilitate a continuous production for the
entire production line as a function of the batch size and the
respective retrofit time.
[0063] FIG. 9 is based on the subsequent general formula according
to which the first and the second product buffer have the same
buffer capacity and the temporarily upstream connected production
line section and the downstream production line section have the
same production speed:
Difference of production speeds=retrofit time.times.(production
speed of the production line section).sup.2/batch size, wherein
batch size=emptying time of product buffer*production speed of the
upstream production line section.
Emptying time of product buffer=buffer capacity of product
buffer/(increased production speed of the temporarily
discontinuously operating processing station-production speed of
the upstream production line section).
Buffer capacity of the product buffer=retrofit
time.times.production speed of upstream production line
section.
* * * * *