U.S. patent application number 16/045885 was filed with the patent office on 2019-01-31 for method for the production of a series of containers comprising a step for marking containers.
The applicant listed for this patent is SIDEL PARTICIPATIONS. Invention is credited to Laurent DANEL, Yves-Alban DUCLOS, Franck FEILLOLEY, David GARIOU, Cyrille LECANU, Stephane LINGLET, Christophe MARAN, Sebastien MOULIN.
Application Number | 20190031383 16/045885 |
Document ID | / |
Family ID | 60765730 |
Filed Date | 2019-01-31 |
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United States Patent
Application |
20190031383 |
Kind Code |
A1 |
FEILLOLEY; Franck ; et
al. |
January 31, 2019 |
METHOD FOR THE PRODUCTION OF A SERIES OF CONTAINERS COMPRISING A
STEP FOR MARKING CONTAINERS
Abstract
Method for the production of containers from a series of plastic
preforms heated in a container production facility having at least
one heating station, a forming machine with a number of forming
stations, one or more treatment machines with a number of treatment
stations. The method includes: forming the preforms in the forming
machine; treating the individual containers in the treatment
machine; and circulating each container held individually between
the forming machine and the treatment machine(s). The method also
includes individual identification of each container that is
produced during a predetermined tracking period, an individual
identification phase including a marking step during which each
individual container that is produced during the tracking period
receives a marking that matches the container, making it possible
to identify individually the container by distinguishing it from
all of the other containers produced by the production facility
during the tracking period.
Inventors: |
FEILLOLEY; Franck;
(Octeville-Sur-Mer, FR) ; DANEL; Laurent;
(Octeville-Sur-Mer, FR) ; LINGLET; Stephane;
(Octeville-Sur-Mer, FR) ; DUCLOS; Yves-Alban;
(Octeville-Sur-Mer, FR) ; MARAN; Christophe;
(Octeville-Sur-Mer, FR) ; MOULIN; Sebastien;
(Octeville-Sur-Mer, FR) ; LECANU; Cyrille;
(Octeville-Sur-Mer, FR) ; GARIOU; David;
(Octeville-Sur-Mer, FR) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
SIDEL PARTICIPATIONS |
Octeville-Sur-Mer |
|
FR |
|
|
Family ID: |
60765730 |
Appl. No.: |
16/045885 |
Filed: |
July 26, 2018 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B65C 3/06 20130101; B29C
49/78 20130101; B29K 2067/003 20130101; B67C 7/004 20130101; B29L
2031/7158 20130101; B29C 2049/2404 20130101; B67C 2007/0066
20130101; B29C 49/36 20130101; B65B 61/025 20130101; B67C 2007/006
20130101; B29C 49/06 20130101; B29C 49/46 20130101; B29C 49/24
20130101; B29C 49/6418 20130101; B29C 2049/4664 20130101 |
International
Class: |
B65B 61/02 20060101
B65B061/02; B65C 3/06 20060101 B65C003/06; B67C 7/00 20060101
B67C007/00; B29C 49/46 20060101 B29C049/46; B29C 49/64 20060101
B29C049/64; B29C 49/78 20060101 B29C049/78 |
Foreign Application Data
Date |
Code |
Application Number |
Jul 31, 2017 |
FR |
1757283 |
Claims
1. Method for the production of a series of containers (2) from a
series of preforms (4) made of plastic materials that are heated in
a container production facility (1) that comprises at least one
station (6) for heating the series of preforms (4), a forming
machine (8) that comprises a number of forming stations (24), one
or more treatment machines (34) that each comprise a number of
treatment stations (36), with the method comprising the following
steps: Circulation of the series of preforms (2) in the heating
station (6) up to the forming machine during which each preform (4)
is held individually and heated at a reference temperature, Forming
of the series of preforms (4) in the forming machine (8), each
heated preform (4) being placed in a forming station (24) in which
said preform (4) is formed into a container (2), in such a way that
said series of preforms (4) is formed into a series of individual
containers (2), Treatment of the series of individual containers
(2) in the treatment machine (34, 10, 46), with each individual
container (2) being placed in a treatment station (36, 40, 48),
Circulation of each container that is held individually between the
forming machine and the treatment machine(s), the method further
comprising a phase for individual identification of each container
that is produced during a predetermined tracking period, an
individual identification phase comprising a marking step during
which each individual container (2) that is produced during said
tracking period receives a marking that matches said container,
making it possible to identify individually said container by
distinguishing it from all of the other containers produced by the
production facility during said tracking period.
2. Production method according to claim 1, in which the marking
that matches the container that is to be identified comprises
station information relative to at least one of the elements that
has held, or is supposed to hold, said container that is to be
identified during the production of the container that is to be
identified, and time-stamping information (62) relative to the time
when said container (2) that is to be identified is marked.
3. Production method according to claim 2, in which the
time-stamping information (62) comprises the date and the hour (68)
within the second at which the marking (52) of the container (2)
takes place.
4. Production method according to claim 1, in which the marking
that matches the container that is to be identified comprises a
chronology number of the production of the container during the
tracking period.
5. Production method according to claim 1, in which the marking
that matches the container that is to be identified also comprises
a coding that matches the facility that has produced said container
and/or a coding of the tracking period.
6. Production method according to claim 1, comprising a step for
applying a barrier layer to the series of containers (2), with one
of said treatment machines being a machine (34) for application of
said barrier layer onto the inner wall of the container (2) that
comprises a number of application stations (36), with each
container (2) being placed in an identified application station
(36) in which a barrier layer is applied onto the inner wall of
said container, the step for marking the container (2) that is to
be identified comprising the marking (52) of a piece of information
(58) relative to the identified application station in which a
barrier layer has been or will be applied to said container.
7. Production method according to claim 6, comprising another
treatment step that is a step for filling each container that is
produced, with one of the corresponding treatment machines being a
filling machine, the step for marking the container that is to be
identified taking place between the step for applying a barrier
layer and the filling step.
8. Production method according to claim 7, in which the facility
that comprises a capping unit (46) that comprises a number of
capping stations (48); method in which, during the step for capping
the series of containers (2), each container (2) is placed in an
identified capping station (48) in which a cap is attached to said
container (2), with the step for marking the container (2) that is
to be identified comprising the marking (52) of a piece of
information (60) relative to the identified capping station (48) in
which a cap has been attached to said container (2).
9. Production method according to claim 7, in which the marking
step comprises the marking (52) of a piece of product information
(70) pertaining to the filler product that is introduced into the
container (2) during the filling step.
10. Production method according to claim 1, in which the production
facility comprises a labeling unit that has a number of labeling
stations; method in which, during the labeling step, each container
(2) is placed in an identified labeling station in which a label is
attached to said container, with the step for marking the container
that is to be identified comprising the marking (52) of a piece of
information (58) relative to the identified labeling station in
which a label has been attached to said container.
11. Production method according to claim 1, in which the marking
(52) of each container (2) is carried out in a unique zone of said
container (2), with the information (54, 58, 56, 60, 62) relative
to the identified stations and time-stamping being placed adjacent
to one another in said unique zone.
12. A production facility's method for controlling a series of
containers (2) from a series of preforms (4) made of plastic
materials comprising: A first step of machine data acquisition
implementing the method according to claim 1, in which for each
individual container that is produced, the control console records,
on the one hand, the marking that matches said container, and, on
the other hand, a series of specific data relative to the forming
and/or treatment stations and/or relative to the elements that have
held said container during its production, and/or a series of
general data relative to the operation of the facility during the
production of said container, A second step of container data
acquisition, during which one or more physical values of each of
the individually identified containers is/are measured during the
first step, A third step of compiling a mixed database that
matches, for each individually identified container during the
first step, on the one hand, the measurement(s) of the second step,
and the series of data acquired during the first step.
13. Control method according to claim 12, comprising a diagnostic
step, during which the container data are compared in relation to
pre-set target values that correspond to the measured values, and a
detected or imminent malfunction at one or more of the forming
and/or treatment stations and/or holding elements of the facility
is determined.
14. Control method according to claim 12, comprising a step for
analysis of the mixed database, during which at least one law of
correlation between the container data and the machine data is
established, and a correction step in which according to the
correlation law(s), one or more likely adjusted machine parameters
is/are calculated during the next production cycle for producing
containers, one or more physical values of which will be closer to
the pre-set target(s) than during the first step.
15. Facility (1) for production of a series of containers (2) from
a series of preforms (4) made of heated plastic materials making it
possible to implement a production method according to claim 2,
with said facility comprising: A station (6) for heating the series
of preforms (4) making it possible to hold and to heat each of said
preforms (4) at a reference temperature, A machine (8) for forming
the series of preforms (4) into a series of containers (2), with
said forming machine (8) comprising a number of identified forming
stations (24), each forming station (24) receiving a preform (4)
and forming said preform into a container (2), At least one machine
(34) for treatment of the series of containers (2), with said
treatment machine (34) comprising a number of stations (36) for
treatment of the container that is produced, A positive transport
device (12) that holds each container individually between the
forming machine (8) and the treatment machine(s) (34, 10, 46), A
marking unit (14) that applies a marking (52) to each of the
containers (2) of the series of containers, and a control console
(27) that is connected to the marking unit (14) and that generates
the marking that is to be applied, with said production facility
(1) being wherein the control console comprises software that is
designed so that said marking (52) matches said container and makes
it possible to identify individually each container that is
produced during a predetermined tracking period by distinguishing
it from all of the other containers that are produced by the
production facility during said tracking period.
16. Production facility according to claim 15, in which each
preform that circulates in the heating station is held by a
gripping element; each individual container in the process of
forming is held by the forming station (24) that forms it; each
individual container in the course of treatment is held by the
treatment station (36) that treats it; each individual container
that circulates between the forming machine and the treatment
machine(s) is held by an element for gripping the positive
transport device (12); said gripping elements, the forming station
or the station for treatment of the or each treatment machine
constitute elements that have held, or that should hold, the
container that is to be identified, on which information is
recorded in the control console that is associated with the marking
that matches the container that is to be identified.
17. Production facility according to claim 15, in which one of the
treatment machines is a machine for filling the container that is
produced by the facility, with the filling machine (10) comprising
a number of filling stations (40), and in which each filling
station (40) of the filling machine (10) is combined with an
identified forming station (24) of the forming machine (8) in such
a way that for each filling station (40), the control console knows
from which forming station (24) the container that the filling
station is in the process of filling systematically comes.
18. Production method according to claim 2, in which the marking
that matches the container that is to be identified also comprises
a coding that matches the facility that has produced said container
and/or a coding of the tracking period.
19. Production method according to claim 3, in which the marking
that matches the container that is to be identified also comprises
a coding that matches the facility that has produced said container
and/or a coding of the tracking period.
20. Production method according to claim 4, in which the marking
that matches the container that is to be identified also comprises
a coding that matches the facility that has produced said container
and/or a coding of the tracking period.
Description
[0001] The invention relates to the field of the production of
containers (in particular bottles, flasks) by forming from preforms
made of plastic material, such as, for example, polyethylene
terephthalate (PET), with the containers being filled with a filler
product.
[0002] In such a facility, the forming of containers from preforms
and a treatment series of these containers are combined in the
continuation of the production of containers, such as filling,
capping. It is also known to label and/or to mark the container on
line.
[0003] During the use of the production facility, certain
malfunctions are likely to occur and result in, for example,
misshapen containers, destroyed containers, or leaks during
filling. To detect the defective containers, it is known to provide
various sensors in the facility, for example cameras or the like,
and it is provided to evacuate the sub-standard containers from the
facility so that they are not filled with the filler product.
[0004] However, such means do not make it possible to work back to
the cause of the malfunction nor to detect other problems that may
occur in the facility, for example during filling or in particular
units of the facility. Actually, the sensors make it possible to
detect a defective container but the analysis of the cause of this
fault remains difficult.
[0005] To overcome this drawback, it is possible, for example, to
provide that the container is marked by each element of the
facility that makes possible its forming, its filling and all of
the treatments that it is likely to undergo so as to make it
possible to trace the path of the container in the facility.
However, the multiplicity of the markings makes complications for
the facility and is likely to weaken the container by increasing
the marked zones of the container. In addition, even by adding
several markings, it is not possible to identify each container in
a unique way, since several containers that pass through the same
elements of the facility will have an identical marking.
[0006] The invention relates in particular to container production
facilities that ensure a series of treatments on each container and
that individually hold each container during the entire treatment
process of the container in the production facility. Such
facilities have a monitoring system that can record in real time
the values that are measured or detected by a large number of
sensors of the machine, can record the beginning of a large number
of operations carried out on the container and can relate to each
container a large amount of machine data relative to each
individual container.
[0007] However, the analysis of a fault in the container may
necessitate testing this container after the latter has left the
facility. For example, when the facility comprises the deposition
of a layer on a surface of the container, it may be useful to
initiate a long manual test that cannot be carried out on line at
the production rate. Sometimes, the pertinent test for detecting an
origin of a fault can be a test that destroys the container.
Problems arise when, after the container has left the facility, the
link to the monitoring system of the facility is broken. It is
difficult to make the connection between the result of an
"off-line" test and the record of what the production facility has
done on this particular container.
[0008] One of the objects of the invention is to propose a method
for production of a series of containers, making it possible to
broaden the analysis of the faults and/or the deviations that can
occur at a container production facility.
[0009] For this purpose, the invention relates to a method for the
production of a series of containers from a series of preforms made
of plastic materials that are heated in a container production
facility comprising at least one station for heating the series of
preforms, a forming machine that comprises a number of forming
stations, one or more treatment machines that each comprise a
number of treatment stations, with the method comprising the
following steps: [0010] Circulation of the series of preforms in
the heating station up to the forming machine during which each
preform is held individually and heated at a reference temperature,
[0011] Forming of the series of preforms in the forming machine,
each heated preform being placed in a forming station in which said
preform is formed into a container, in such a way that said series
of preforms is formed into a series of individual containers,
[0012] Treatment of the series of individual containers in the
treatment machine, each individual container being placed in a
treatment station, [0013] Circulation of each container that is
held individually between the forming machine and the treatment
machine(s),
[0014] with the method comprising a phase for individual
identification of each container that is produced during a
predetermined tracking period, an individual identification phase
comprising a marking step during which each individual container
produced during said tracking period receives a marking that
matches said container, making it possible to identify individually
said container by distinguishing it from all of the other
containers produced by the production facility during said tracking
period.
[0015] Owing to the individual identification that matches each
container that is produced, it is possible to make the connection
between measurements made a posteriori after the production of the
container and all of the machine data relative to the production of
this particular container. This to improve the ability to analyze
faults and/or predictive maintenance of the facility.
[0016] The forming and treatment stations hold the preform or the
container that is placed there. Thus, the container production
facility ensures the individual holding of the preform or the
container throughout the production process of this container.
[0017] The predetermined tracking period can be contractual and
cover the entire life of the production facility. Alternatively, it
can be selected by the operator and target a particular
investigation phase of the facility.
[0018] According to another characteristic of the method according
to the invention, the marking that matches the container that is to
be identified comprises station information relative to at least
one of the elements that have held, or should hold, said container
that is to be identified during the production of the container
that is to be identified, and time-stamping information relative to
the moment when said container that is to be identified is
marked.
[0019] Owing to the fact that preforms and containers are held
individually during their entire passages into the production
facility, it is possible to know at each moment the position of
each preform or container in the facility and thus to identify the
various stations through which a preform and then the container
that is formed from this preform pass. Thus, in a unique marking
step, it is possible to add to the marking information on the
stations through which the container has passed. Thus, the
container is not weakened by increasing the number of the marking
steps and zones. In addition, owing to the time-stamping
information at the moment of marking, it is possible to identify
each container in a unique way. Actually, the markings of two
containers that have passed through the same stations of the
production facility will be distinguished from one another by the
information at the moment in which the marking has taken place.
[0020] Advantageously, the time-stamping information comprises the
date and the time to within one second when the marking of the
container took place.
[0021] The inventors noted that time-stamping information to within
one second is adequate for identifying each container in a unique
way. Actually, the production cycles of the facility are such that
two containers cannot pass through the same stations within the
same second. Thus, time-stamping to within one second makes it
possible to distinguish two containers from one another, even if
the latter have passed through the same stations.
[0022] According to a variant, the marking that matches the
container that is to be identified comprises a chronology number of
the production of the container during the tracking period.
Chronology number is defined as any series of alphanumeric codes or
the like that can be classified according to an order, in such a
way that the order of the markings corresponds to the order of
production of the containers.
[0023] According to an embodiment, the marking that matches the
container that is to be identified also comprises a coding that
matches the facility that has produced said container and/or a
coding of the tracking period. Such an embodiment can make it
possible to identify a container that is produced according to this
method by distinguishing it from all of the others, optionally
produced by another machine. Thus, the marking can be used as a
basis for detecting duties.
[0024] According to another characteristic of the method according
to the invention, one of said treatment machines is a machine for
application of said barrier layer to the inner wall of the
container that comprises a number of application stations, with the
method comprising a step for application of a barrier layer to the
series of containers, each container being placed in an identified
application station in which a barrier layer is applied to the
inner wall of said container, with the marking step of the
container that is to be identified comprising the marking of
information relative to the identified application station in which
a barrier layer has been or will be applied to said container.
[0025] The identification of the station that has carried out the
application of the barrier layer is particularly useful for the
off-line monitoring of permeability. Actually, the barrier layer
makes it possible to improve the impermeability to gas of the
container, for example for preventing carbon dioxide (CO.sub.2)
from escaping from the container through the wall of the latter
when the container contains a carbonated product or for preventing
the oxidation by ambient air of a product that is contained in the
container. So as to evaluate the quality of the barrier layer, it
is necessary to carry out permeability tests outside of the
facility, and it is therefore useful to identify in a specific way
the application station that produced the barrier layer in the
tested container.
[0026] According to other characteristics of the method according
to the invention: [0027] The method comprises another treatment
step that is a step for filling each container that is produced,
with one of the corresponding treatment machines being a filling
machine, the step for marking the container that is to be
identified taking place between the step for application of a
barrier layer and the filling step. [0028] The facility comprises a
capping unit that comprises a number of capping stations; method in
which, during the capping step of the series of containers, each
container is placed in an identified capping station in which a cap
is attached to said container, with the marking step of the
container that is to be identified comprising the marking of
information relative to the identified capping station in which a
cap has been attached to said container. [0029] The marking step
comprises the marking of a piece of product information pertaining
to the filler product that is introduced into the container during
the filling step. [0030] The production facility comprises a
labeling unit that has a number of labeling stations; method in
which, during the labeling step, each container is placed in an
identified labeling station in which a label is attached to said
container, with the marking step of the container that is to be
identified comprising the marking of information relative to the
identified labeling station in which a label has been attached to
said container.
[0031] As indicated above, the positive transport of the preforms
and containers makes it possible to identify easily each of the
stations through which a preform and then the container, obtained
from this preform, pass. Thus, it is possible to add during the
marking the information relative to these stations so as to improve
the traceability of the container.
[0032] The marking step can also be used to mark usual information
on the filler product that is contained in the container, such as,
for example, an expiration date or the like. Thus, a single marking
step makes it possible to print information relative to the
traceability of the container and relative to the product that is
contained in the container.
[0033] According to another characteristic of the method according
to the invention, the marking of each container is carried out in a
unique zone of said container, with the information relative to the
identified stations and the time-stamping stations being placed
adjacent to one another in said unique zone.
[0034] By providing a unique marking zone, the risks of damage to
the containers are limited, and the reading of information marked
on the container is simplified.
[0035] According to another aspect, the invention relates to a
production facility's method for controlling a series of containers
from a series of preforms made of plastic materials comprising:
[0036] A first step of machine data acquisition implementing the
above-cited method, in which for each individual container that is
produced, the control console records, on the one hand, the marking
that matches said container, and, on the other hand, a series of
specific data relative to the forming and/or treatment stations
and/or relative to the elements that have held said container
during its production, and/or a series of general data relative to
the operation of the facility during the production of said
container, [0037] A second step of container data acquisition,
during which one or more physical values of each of the
individually identified containers is/are measured during the first
step, [0038] A third step of compiling a mixed database that
matches, for each individually identified container during the
first step, on the one hand, the measurement(s) of the second step,
and the series of data acquired during the first step.
[0039] According to an embodiment, the control method comprises a
diagnostic step, during which the container data are compared
against pre-set target values corresponding to measured values, and
a detected or imminent malfunction at one or more of the torming
and/or treatment stations and/or holding elements of the facility
is determined. The detection of an imminent fault can be detected
by measuring a derivative of a container datum and/or a machine
datum and by detecting that this derivative exceeds a pre-set
threshold.
[0040] According to another embodiment, the control method
comprises a step for analysis of the mixed database, during which
at least one law of correlation between the container data and the
machine data is established, and a correction step in which
according to the correlation law(s), one or more likely adjusted
machine parameters is/are calculated during the next production
cycle for producing containers, one or more physical values of
which will be closer to the pre-set target(s) than during the first
step.
[0041] According to another aspect of the invention, the facility
for production of a series of containers from a series of preforms
made of heated plastic materials making it possible to implement an
above-mentioned production method, with said facility comprising:
[0042] A station for heating the series of preforms making it
possible to hold and to heat each of said preforms at a reference
temperature, [0043] A machine for forming the series of preforms
into a series of containers, with said forming machine comprising a
number of identified forming stations, each forming station
receiving a preform and forming said preform into a container,
[0044] At least one machine for treatment of the series of
containers, with said treatment machine comprising a number of
stations for treatment of the container that is produced, [0045] A
positive transport device that holds each container individually
between the forming machine and the treatment machine(s), [0046] A
marking unit that applies a marking to each of the containers of
the series of containers, and a control console that is connected
to the marking unit and that generates the marking that is to be
applied,
[0047] with said production facility being characterized in that
the control console comprises software that is designed so that
said marking matches said container and makes it possible to
identify individually each container that is produced during a
predetermined tracking period by distinguishing it from all of the
other containers that are produced by the production facility
during said tracking period.
[0048] According to an embodiment, each preform that circulates in
the heating station is held by a gripping element; each individual
container in the process of forming is held by the forming station
that forms it; each individual container in the course of treatment
is held by the treatment station that treats it; each individual
container that circulates between the forming machine and the
treatment machine(s) is held by an element for gripping the
positive transport device; said gripping elements, the forming
station or the station for treatment of the or each treatment
machine constitute elements that have held, or that should hold,
the container that is to be identified, on which information is
recorded in the control console that is associated with the marking
that matches the container that is to be identified.
[0049] The invention is particularly advantageous in the case where
the stations of the various machines are "paired," i.e., the two
stations of two different machines operate cooperatively to treat a
preform and the container that is obtained from the preform. In
other words, the containers that are formed from preforms that were
passed through a particular forming station of the forming machine
will always be filled by the same filling station of the filling
station. Thus, the path is known that is followed by a preform and
a container that is obtained from the preform as soon as the
forming station through which the preform passes is known.
Consequently, the marking is simplified since the information that
is marked on two containers that have passed through the same
stations are identical except for the time-stamping
information.
[0050] According to an embodiment, one of the treatment machines is
a machine for filling the container that is produced by the
facility, with the filling machine comprising a number of filling
stations, and in which each filling station of the filling machine
is combined with an identified forming station of the forming
machine in such a way that for each filling station, the control
console knows from which forming station the container that the
filling station is in the process of filling systematically
comes.
[0051] Other aspects and advantages of the invention will become
clear from reading the following description, provided by way of
example and given with reference to the accompanying drawings, in
which:
[0052] FIG. 1 is a diagrammatic top representation of a production
facility according to the invention,
[0053] FIG. 2 is a diagrammatic representation of a container that
is obtained after the marking step of the production method
according to the invention,
[0054] FIG. 3 is a representation of the information marked on a
container after the marking step of the production method according
to the invention, and
[0055] FIGS. 4a, 4b illustrate two marking examples, a QR code
(FIG. 4a), and a data matrix (FIG. 4b).
[0056] With reference to FIG. 1, a facility 1 for production of a
series of containers 2 from a series of preforms 4 made of plastic
material is described.
[0057] The production facility 1 comprises at least one heating
station 6, a forming machine 8, a filling machine 10, a transport
device 12, and a marking unit 14.
[0058] Each preform 4 comprises a body 16, a neck 18, and a ring
20. The body 6 has, for example, the shape of a test tube with a
closed bottom and defines an inner volume that extends along a main
axis A. The neck 8 extends in the continuation of the body 6
opposite the bottom and forms an upper opening through which a
fluid can be introduced into the inner volume of the preform, as
will be described later. The neck 8 of the preform has, for
example, the definitive shape that it will have in the container 2
that is formed from the preform 4 and comprises, for example, a
threading on its outer wall to make it possible to attach a cap to
the container. The ring 10 extends between the body 6 and the neck
8 radially toward the outside and forms, for example, a transport
ring by which the preform can be gripped and transported, as will
be described subsequently. The form of the preform that is provided
above is only by way of example, and other forms could be
considered, as long as the latter are appropriate for forming a
container by introduction of a fluid into the preform. Thus, by way
of example, the preform could have a smooth neck, be lacking a
ring, and/or have other form variants according to various preform
models that can be used in the production facility 1. The plastic
material of the preform is, for example, polyethylene terephthalate
(PET). As a variant, the plastic material could be different from
PET, as long as this material is able to be made malleable and
deformable to make possible the production of a container by
introduction of a fluid into the preform.
[0059] The heating station 6 is arranged to heat each preform 4 at
a reference temperature at which the preform 4 is in a malleable
state and can be formed into a container. The reference temperature
is between the glass transition temperature and the crystallization
temperature of the material of the preform 4. The heating station 6
comprises, for example, a number of heating elements that are
distributed in the heating station 6 along a path and arranged to
heat the series of preforms 4 that move before the heating elements
owing to the transport device 12. The heating elements are, for
example, in addition distributed in a direction that is parallel to
the axes of the preforms in such a way as to make it possible to
heat the entire body 6 of the preforms 4. With such a heating
station 6, or moving furnace, being known in the art, it will not
be described in more detail here.
[0060] At the outlet of the heating station 6, the heated preforms
are moved to the forming machine 8 by the transport device 12.
[0061] The transport device 12 is formed by, for example, a
conveyor in the heating station 6. At the outlet of the heating
station 6, the transport device 12 is, for example, formed by a
number of transfer wheels 22 that can rotate, each provided on the
periphery with a number of gripping elements. Each gripping
element, for example of the clamp type or the like, is arranged to
grip a preform 4 from the series of preforms and to transport it to
the next wheel where an element for gripping the next wheel removes
the preform and so on up to the forming machine 8. The number of
wheels can vary from one production facility to the next and
depends on the arrangement of the production facility. A single
wheel could be provided between the outlet of the heating station 6
and the forming machine 8, as shown in FIG. 1.
[0062] The transport device 12 is a positive transport device,
i.e., the transport device 12 is arranged so that the position of a
preform 4 is always known in the production facility 1. This can be
achieved in particular by driving one or more wheels in rotation by
means of a synchronous motor and by slaving the rotation of the
other wheels to the wheel that is driven in rotation by the
synchronous motor, for example by means of belts. Another approach
consists in driving in rotation each wheel by means of a
synchronous motor. Actually, the angular position of a synchronous
motor is known at any moment, and it is therefore possible to
deduce from it the position of a preform 4 in the production
facility using the knowledge of the angular position of the wheels
at each moment.
[0063] The forming machine 8 comprises a number of forming stations
24 that are each arranged to receive and form a preform 4 from the
series of preforms 4 into a container. For this purpose, each
forming station 24 comprises a mold 26 and a device for injecting a
forming fluid. The mold 26 comprises a molding cavity that has the
shape of the container that is to be produced and arranged to
receive the body 6 of the preform. The injection device is arranged
to inject a forming fluid under pressure into the inner volume of
the preform 4 through the upper opening of the latter so that the
body 6 of the preform acquires the shape of the molding cavity. The
forming fluid is, for example, a gas, for example pressurized air.
Each forming station 24 can also comprise a stretching rod that is
arranged to provide support on the bottom of the preform 6 so as to
extend it along its axis.
[0064] Each forming station 24 is identified, i.e., it is
referenced in a control console 27 of the facility. Thus, by way of
example, the forming machine 8 comprises 28 forming stations. For
reasons of simplicity and to facilitate the reading of the figure,
only five forming stations 24A, 24B, 24C, 24D and 24E. The forming
stations 24 are carried by a forming wheel 28 or carrousel that can
rotate around an axis of rotation that is parallel to the axes of
rotation of the transfer wheels 22. The forming stations 24 are
carried on the periphery of the forming wheel 28 in such a way that
they move along a circular path that is defined by the forming
wheel 28 between an entry point 30 and an exit point 32. At the
entry point, the mold is open and is arranged to receive a preform
4 from the transfer wheel 22, and then the mold 26 is closed, the
injection device is put into fluidic communication with the inner
volume of the preform, and the forming fluid is injected into the
preform while it is moving from the forming station between the
entry point 30 and the exit point 32. At the exit point 32, the
mold 26 is open and the formed container is extracted from the
forming station 24. The structure and the operation of such forming
stations 24 and, more generally, the forming machine 8 are known as
such and will not be described in more detail here.
[0065] It should be noted that in the forming machine 8, the
transport device 12 is formed by the forming wheel 28 and the molds
themselves that transport the preforms and the containers from the
entry point 30 to the exit point 32. The forming wheel 28 is thus
driven in such a way as to know the positions of the forming
stations 24 at any moment, for example by driving the forming wheel
28 by means of a synchronous motor. Consequently, the facility
makes it possible to know in what forming station 24 a preform 4 is
placed and formed into a container. The control console 27 thus
records into which forming station 24A, 24B, . . . , 24E a
particular preform passes.
[0066] At the exit point 32 of the forming machine 8, the transport
device 12 comprises a transfer wheel that is arranged to remove the
containers 2 at the outlet of the forming machine 8 and to transfer
them to the filling machine 10.
[0067] The containers that are obtained, one example of which is
shown in FIG. 2, comprise a body 33 that is obtained by forming the
body 16 of the preform, a neck 18 and a ring 20 that are identical
to the neck 18 and to the ring 20 of the preform 4 since the latter
are not modified during the forming. The body 33 comprises, for
example, a shoulder 35 that forms the connection between the neck
18 and a cylindrical part of the body of the container 2.
[0068] According to variant embodiments of the production facility,
one or more units 34 for treatment of the series of containers 2
can be provided between the forming machine 8 and the filling
machine 10. Each treatment unit 34 comprises a number of identified
treatment stations 36 that are arranged to apply a particular
treatment to the containers 2 from the series of containers and are
carried by, for example, a handling wheel 38. As for the forming
machine 8, in the treatment unit 34, the transport device 12 is
formed by the handling wheel 38, and the treatment stations 36
themselves and the handling wheel 38 are arranged in such a way
that it is known by which identified treatment station 36 a
container 2 from the series of containers is treated. The control
console 27 thus records into which treatment station a particular
container passes.
[0069] The transport device 12 is also arranged to transfer the
containers 2 between the exit points of a treatment unit 34 to the
entry point of another treatment unit 34 and up to the filling
machine 10. It should be noted that the transfer wheels 22 of the
transfer device can also make it possible in a known way to modify
the span between two successive preforms 4 or containers 2 to adapt
this span to the number of treatment stations 36 provided in the
treatment units 34. Actually, the forming machine 8, the filling
machine 10, and the various treatment units 34 do not necessarily
comprise the same number of stations, this number of stations
depending on the amount of space required by the latter on a wheel
and on the handling rate of the stations. Actually, the stations
should make it possible to carry out the handling in one turn of
the handling wheel. The gripping elements of the transport device
12 are, for example, adapted for transporting the containers 2 by
their rings 20.
[0070] By way of example, the treatment unit 34 can be a labeling
unit that makes it possible to label each container 2, i.e., to
apply a label on each container. For this purpose, the labeling
unit comprises a number of identified labeling stations that are
each arranged to receive a container and to apply a label on said
container. The labeling stations are, for example, carried by a
labeling wheel that can rotate and that moves the containers in a
positive way between an entry point and an exit point, with the
labels being applied to the containers during this movement.
[0071] As a variant or in addition, the treatment unit 34 or
another treatment unit can be a unit for application of a barrier
layer on the inner wall of the containers 2. The application unit
comprises a number of application stations that are each arranged
to apply a barrier layer on the inner wall of a container 2 that is
received into said application station. Such an application station
is described in, for example, the document FR-2 907 351. The
application stations are, for example, carried by an application
wheel that can rotate and that moves the containers in a positive
way between an entry point and an exit point, with the application
stations applying the barrier layer on the containers during this
movement.
[0072] As a variant or in addition, the treatment unit 34 or
another treatment unit can be a unit for cleaning containers that
is arranged to inject a cleaning product into the containers.
[0073] For reasons of simplicity and to facilitate the reading of
the figure, only a treatment unit 34 that comprises five treatment
stations 36 has been shown in FIG. 1. It is understood, however,
that several treatment units 34, comprising a different number of
treatment stations, can be provided.
[0074] The filling machine 10 comprises a number of filling
stations 40 that are each arranged for receiving and filling a
container 2 from the series of containers 2. For this purpose, each
filling station 40 comprises a support for a container 42 and a
device for filling the container. The filling device is arranged to
introduce a filler product into the inner volume of the container 2
via the upper opening of the latter. The filler product is, for
example, a liquid, which can be more or less viscous, carbonated or
not, and can comprise solid pieces. The filler product may be
cooled to ambient temperature or to a warm temperature.
[0075] Each filling station 40 is identified, i.e., it is
referenced in the control console 27 of the facility. Thus, by way
of example, the filling machine 10 comprises 120 filling stations
40. For reasons of simplicity and to facilitate the reading of the
figure, only five filling stations 40A, 40B, 40C, 40D and 40E. The
filling stations 40 are carried by a filling wheel 44, or carrousel
that can rotate around an axis of rotation that is parallel to the
axes of rotation of the transfer wheels 22. The filling stations 40
are carried on the periphery of the filling wheel 44 in such a way
that they move along a circular path that is defined by the filling
wheel 44 between an entry point and an exit point. At the entry
point and the exit point, the filling device is placed opposite the
inner volume of the container 2, and the filler product is
introduced into the container during the movement from the filling
station. At the exit point, the filled container is extracted from
the filling station 40. The structure and the operation of such
filling stations 40 and, more generally, of the filling machine 10
are known as such and will not be described in more detail
here.
[0076] It should be noted that in the filling machine 10, the
transport device 12 is formed by the filling wheel 44 and the
container supports 42 themselves that transport the containers from
the entry point to the exit point. The filling wheel 44 is thus
driven in such a way as to know the position of the filling
stations 40 at any moment, for example by driving the filling wheel
44 by means of a synchronous motor. Consequently, the facility
makes it possible to know in which filling station a container 2 is
placed and filled. The control console 27 thus records into which
filling station 40A, 40B, . . . , 40E a particular container
passes.
[0077] At the outlet of the filling machine 10, the transport
device 12 comprises one or more transfer wheels 22 that transport
the containers that are filled to a capping unit 46, comprising a
number of capping stations 48 that are driven in rotation by a
capping wheel 50, each arranged to apply a cap to the neck 18 of a
container 2 from the series of containers. As for the other units
and machines of the facility, in the capping unit, the transport
device 12 is formed by the capping wheel 50 and the capping
stations 48 themselves, and the capping wheel 50 is driven in such
a way as to know the position of the capping stations 48 at any
moment, for example by driving the capping wheel 50 by means of a
synchronous motor. Consequently, the facility makes it possible to
know in which capping station a container 2 is placed. The control
console 27 thus records into which capping station 50 a particular
container passes.
[0078] At the outlet of the capping unit 50, the containers 2 are
removed from the production facility 1.
[0079] The marking device 14 is arranged to apply a marking 52
(FIGS. 2 and 3) on each container 2 from the series of containers.
Such a marking can be carried out by printing with ink, by the
application of a label, by engraving, etc. The marking device 14
can be placed between the forming machine 8 and the filling machine
10, for example opposite a transfer wheel 22. According to a
particular example, the marking device 14 is placed between the
unit for applying a barrier layer and the filling machine 10.
According to an embodiment, the production facility 1 comprises a
unique marking device 14. As a variant, the production facility 1
comprises several marking devices 14, each arranged for marking a
portion of the containers, while another portion is marked by
another marking device. In any case, each container 2 receives only
a unique marking 52 in a particular and unique zone of the
container 2. For example, the marking 52 is carried out on a
portion of the shoulder 35 of the container 2, as shown in FIG. 2.
Such a marking that is unique and produced in a unique zone of the
container 2 makes it possible to limit the interactions of the
marking device 14 with the wall of the container 2 and thus the
risks of damage to the container. The marking zone could be
provided other than on the shoulder 35, for example on another
portion of the body 33 of the container 2.
[0080] The marking 52 comprises a number of pieces of information
relative to the routing of the container 2 and the preform from
which it is obtained in the production facility 1. Actually, as
indicated above, the positive transport device 12 makes it possible
to know this routing specifically and more particularly to know
through which stations a particular preform and the particular
recipient obtained from this preform have passed.
[0081] Thus, the marking 52 comprises at least one piece of forming
information 54 relative to the identified forming station 24 in
which the marked container 2 has been formed and a piece of filling
information 56 relative to the identified filling station 40 in
which the marked container was filled. The forming information 54
is, for example, a forming station number that indicates by which
forming station 24A, . . . , 24E the container has been formed, and
the filling information 56 is, for example, a filling station
number that indicates by which filling station 40A, . . . , 40E the
container has been filled. In FIG. 3, a marking example 52 has been
shown, in which the number of the identified forming station 24A, .
. . , 24E is 16 and in which the number of the identified filling
station 40A, . . . , 40E is 61. If necessary, the marking 52 also
comprises at least one piece of treatment information 58 relative
to an identified treatment station 36, in which the container 2 has
been treated. Thus, the treatment information 58 indicates, for
example, the number of the labeling station, of the application
station, or of the cleaning station through which the container 2
has passed. In FIG. 3, the number of the identified treatment
station 36 is 42. According to an embodiment, the marking 52
comprises as much treatment information 58 as there are treatment
units 34 between the forming machine 8 and the filling machine 10.
If necessary, the marking also comprises at least one piece of
capping information 60 relative to the identified capping station
48 in which a cap has been attached to the marked container 2. The
information 60 can advantageously be a schedule number of the
production line 1. This number makes possible the unique
identification of the production line. Without this number, it is
possible (but not very probable) that two bottles comprise the same
identification, if they have been produced on two different lines.
In the example of FIG. 3, the number of the identified capping
station 60 is 062. It should be noted that the marking device 14 is
able to mark information relative to stations that the container
has not yet passed at the time when the marking is being done.
Actually, owing to the positive transport device 12, this
information is available at any moment even before the container
passes through the station in question owing to the synchronization
of the production facility 1 and the different machines and units
between it.
[0082] The marking 52 also comprises time-stamping information 62
relative to the moment at which the container 2 is marked. The
time-stamping information 62 comprises, for example, the calendar
date of the day 64 in the year and the calendar date of the year 66
when the production facility was put into service and began
producing containers. In the example of FIG. 3, the calendar date
of the day 64 is 342 and the calendar date of the year 66 is 05,
which means that the container was marked on the 342.sup.nd day of
the fifth year of production of the production facility. The
time-stamping information 62 also comprises the hour 68 at which
the container 2 is marked. As shown in FIG. 3, the hour 68 is
marked within a second. Actually, such precision is adequate to
ensure a unique marking of each container, even when the containers
have passed through the same stations. Actually, the rotation of a
wheel of a machine or a facility unit lasts for approximately one
second between the entry point and the exit point of this wheel.
Thus, two containers 2 cannot pass into the same station within a
single second.
[0083] An alternative to the unique identification of the bottle by
information relative to the stations for transforming the container
and to time-stamping is a chronology number, combined with a
database that allows the relationship between the unique
identification and the information relative to the stations for
transforming the container.
[0084] The varying marked items of information can be picked up
from the control console 27.
[0085] According to an embodiment, the marking 52 can also comprise
one or more pieces of information regarding product 70, relative to
the filling product that is introduced into the container 2. In the
example of FIG. 3, the information regarding product 70 is an
expiration date of the filler product.
[0086] The varying marked items of information on the product are
placed adjacent to one another, as shown in FIG. 3, in such a way
as to limit the size of the zone in which the marking is carried
out.
[0087] The marking indicated above therefore makes it possible to
identify in a unique way each container 2 of the series of
containers 2 as well as to ensure a complete traceability of the
container in the facility. Such a traceability makes it possible to
identify the possible sources of malfunctions in the facility even
when a fault on a container is noted when this container is no
longer in the production facility. In addition, the time-stamping
information makes it possible to link the information that is
relative to the stations under conditions in which the production
facility was operating at the time of the production of a container
(for example, the temperature in the production facility). In
addition, as indicated above, the unique identification and the
traceability of each container makes it possible to make the
connection between tests that are carried out "on line," i.e., in
the production facility during the path of the container into the
different stations, for example carried out by adequate sensors,
and tests that are carried out "off line," i.e., outside of the
production line of the containers 2.
[0088] According to a variant, the marking that matches the
container can be a QR code or a data matrix, as illustrated in
FIGS. 4a, 4b. This makes it possible to record a large quantity of
data in a compact manner. This information then can be read
directly on the container, without having to resort to the machine
database.
[0089] The invention is particularly advantageous when it is
applied to a production facility in which the synchronization of
machines and units is carried out in such a way that the stations
of these machines and units are said to be "paired." Such a
pairing, known in the art, makes it possible to operate the
stations together in such a way that containers that pass through a
particular forming station 24 of the forming machine 8 always pass
through the same stations downstream from the forming machine 8.
If, for example, a container is formed by the forming station 24A,
this container will be filled by the filling station 40A. Another
container that is formed by the forming station 24A will also be
filled by the filling station 40A. The same is true for the
container treatment stations that will always be the same for the
containers that are formed by the same forming station 24. In other
words, the containers that are formed by a forming station 24 will
always have the same path in the production facility. Thus, the
marked information relative to forming 54, filling 56, and
treatment 58 will be the same for the containers that have passed
through the same forming station 24, and the marking of these
containers differs only by the time-stamping information 62. The
marking is therefore simplified, and the path that is followed by a
container in the production facility is identified very quickly,
which simplifies the detection of possible malfunctions over this
path.
[0090] According to a variant, it is possible to equip the facility
with several marking units. In particular, it is possible to have
the main marking station 14, as described above, and a peripheral
marking unit series, at at least one or at several or at all of the
locations where containers are removed from the facility outside of
the normal production path. Thus, an additional codification can be
added that are ejected from the production for a different reason:
ejection of the container following a production fault; ejection of
the container in the event of an immediate stopping of production;
ejection of containers remaining in the conveying zones, in the
restarting of the production line, or else sampling of the
containers for control.
[0091] All of these ejected containers are found in the same
recovery tank. According to the reason for the ejection of the
article, an additional code is added just before the exit of the
bottle from the normal path of the production.
[0092] A first advantage of this additional codification is to make
possible a manual sorting of the containers in the ejection tank,
typically the separation of the sampled containers for control and
the ejected containers for production fault.
[0093] A second advantage is that the recycling information keeps
bad containers from being in the production circuit. The fault code
that is added to the bottle indicates the attempts to put a
non-compliant product into circulation.
* * * * *