Hymech Engineers Pvt. Ltd. Andheri, Mumbai, Maharashtra

The Wrap around Hotmelt labeling machine is a high speed system ideal for round bottles. It is matched with R.F.C machine and the conveyor connecting both is synchronized to ensure smooth flow of bottles. A stainless steel star wheel or feed worm in case of high speed machines will take the bottle and place in front of the label application drum. The label is delivered by the sensor controls whose response time and control speed frequency of the electronic print mark registration system is very fast, and it works 20 times faster than any other Indian Hotmelt label applicator. The bottle is rolled over the label and on completion of label application, bottle will be discharged on the out feed conveyor. The synchronizing/correction speed is 350 MHZ and response time is 120 micro-seconds. For lower capacity machines to save cost we have developed our own Hotmelt unit, but for higher speed machines we use a Nordson, (U.S.A) system. All electronics used in our system are from leading suppliers such as Siemens, LG, Danfoss who have worldwide service support. The electronic registration system is servo controlled and the fly cutter is synchronized to it to ensure that label is cut with ±1 mm of the print mark. The label cutter is PLC controlled with a hardened tool steel blade. There is an alarm when the label reel starts to run low. If there is no bottle on conveyor, the label will not be delivered to the drum and if there is no label on the drum no adhesive is applied  

Cold filled bottles from the filler are transferred to Warming Tunnel which will have single or multiple temperature zones based on the capacity of the plant. Steam is injected directly into water storage tank to raise its temperature. The heated water is then sprayed over the cold bottles from the filler. The Spray system is made from stainless steel perforated sheets such that entire width and length is covered by water spray. To prevent water from collecting on the bottles an air knife is placed at the outfeed of the machine, which will blow away the excess water.We use MCC make plastic chain and matching sprocket in the cooling tunnel. The main body is made entirely from Stainless Steel.

Non-Returnable glass bottles need to be rinsed before filling. To suit this need the stand alone Rinser was developed. The bottle grippers are made of nylon and custom suited to each bottle shape. The rinser washing nozzles work under positive pump pressure of de-mineralized water, but can also be designed to use ozonized air or a cleaning agent. The bottle is inverted 180° in the rinser to ensure that the cleaning agent is drained before reaching the filler. The entire body above table top level is made of Stainless Steel. It is synchronized with the Filling machine. The drained water can be accumulated and allowed to drain in the tank and re-cycling after re-processing (if required).

To transfer heavier containers (glass, cans, filled plastic bottles) or those that require being body run, Slat Chain conveyors are used.

  It is a fully Stainless Steel Fabricated tunnel with suitable insulation on the outside and perforated Air Distribution Nozzle System.Electric Air Heaters are mounted inside the tube and circulating air blowers are connected into the tunnel. The temperature is controlled electronically as is the speed of the conveyor. The machine can be designed for partial, full body or cap sleeves.

The rinser washing nozzles work under positive pump pressure of de-mineralized water, but can also be designed to use ozonized air or a cleaning agent. The bottle is inverted 180° in the rinser to ensure that the cleaning agent is drained before reaching the filler. The rinser has a No Bottle-No rinse arrangement which prevents wastage of water. The important feature on the R.F.C. is water saving, one can recover 90% of rinse water by collecting in a sump tank and recycle it by sending to the raw water storage tank. There is no chance for contamination by oil, grease and other contaminants from the machine as the rinse water is at all times passed through and is in contact only with stainless steel components, this includes the rinse water after use. The rinser has minimal water wastage and recycles rinse water but ensures a high level of cleaning and so is a economical and eco-friendly mach

Bottles are delivered via conveyor from the Filling machine or loaded manually onto the conveyor. Bottles are taken to the label roller by a star wheel or feed worm (in case of high speed). The bottle is detected and a label is released over bottle which will roll to wrap the label around it. If there is no bottle label is not released. The system will be continuously synchronized by electronic sensing system. Duly labeled bottle will be discharged on the same conveyor for further transfer to packing line.

The Filling valves work on the gravity principle, the water is supplied to the filling bowl by a centrifugal pump, and the water level in the tank is controlled. The bottles are raised to the filling nozzle by positive lift cylinder, if the bottle is not delivered the valve does not open. The water will be filled to pre set level and the bottle is lowered. The lift cylinders operate on positive cam lift-off principle and do not use compressed air or spring load. Lift cylinder cam is made of stainless steel and machined to fine finish and have simple harmonic motion profile to lift bottles smoothly to filling valve. The filling valve works on gravity filling system but has AIR EXHAUST system which removes stagnant air from the bottle to outside atmosphere and do not allow bottle air to mix with ozone atmosphere in filler bowl. The top of the filling bowl/tank is fitted with central manifold to connect all filling valves to single line vent pipe, which can be piped to outside of the filling room. To the same vent pipe reverse flow CIP liquid is connected by isolation butterfly valve. The filling bowl is fitted with Electro-Magnetic type level controller to regulate water level in the bowl through pneumatic ON-OFF valve.

The Jar filling line is a clean and efficient solution for a modern filling plant. It involves a jar brushing machine and a separate Rinsing, filling and capping machine. The brushing machine is manually operated but the Rinser, Filler and Capper is automated after bottle loading. The rinser involves a four stage rinsing system that will use detergent water to clean and treated water to rinse the inside of the jar. The outside of the jar is cleaned by the Jar brushing machine. All the water in the jar or any that is accumulated on the body is allowed to drain off. The jar is tilted 180° during the entire rinsing cycle, after draining the water it is righted once more and sent to the filler. The filler nozzle is controlled pneumatically; it enters the Jars mouth and fills up to a pre-set exact volume. The filling level is controlled by an electronic level controller. The jar then passes under the cap dispenser where it will pick up a cap, the cap is the pneumatically pressed on to the bottle mouth. The jar is then placed on to a pallet manually

This filling system is ideal for liquids such as edible oil, liquid chocolate, araldite which require precise dozing and need to be adjusted for various package sizes. The Filling valves give a positive settable volume dose of the product to be filled. The dose is accurate up to ±2 ml/grams on the set volume. The volume dosing piston is controlled and moved by cam track or by air cylinder. There is a No Bottle-No fill system in place to prevent any wastage. The bottles are raised to the filling nozzle by positive lift cylinder, if the bottle is not delivered the valve does not open. The product will be filled to preset volume and the bottle is lowered. The tank and all rubber components are designed to work at high temperatures. The filling valve is designed with a wide mouth arrangement that it may also be used for filling products with natural pulp/sacs in the liquid. The product is dropped down directly instead of flowing along the sides of the bottle, this prevents and shrinkage and warping in the bottle.

The Filling valves work on the gravity principle, the product is supplied to the filling bowl by a centrifugal pump, and the product level in the tank is controlled. The bottles are raised to the filling nozzle by positive lift cylinder, if the bottle is not delivered the valve does not open. The lift cylinders operate on positive cam lift-off principle and do not use compressed air or spring load. Lift cylinder cam is made of stainless steel and machined to fine finish and have simple harmonic motion profile to lift bottles smoothly to filling valve. The product will be filled to pre set level and the bottle is lowered. The tank and all rubber components are deigned to work at high temperatures. The machine also has a product Recirculation System* to ensure that if machine is stopped for any reason the product in tank is not left to cool. (* optional at extra cost.) The filling valve is designed with a wide mouth arrangement that it may also be used for filling products with natural pulp/sacs in the liquid. The product is dropped down directly instead of flowing along the sides of the bottle, this prevents and shrinkage and warping in the bottle.

Hot filled bottles from the filler will be transferred into the Cooling Tunnel which will have three zone cooling system. Each zone will be maintained at a higher temperature than preceding zones, with the final zone having the lowest temperature which is close to the room temperature. To hold the temperature in first zone, there will be a steam injector system as well as fresh water delivery system.  Both controlled by a digital temperature controller set on heat-cool principle. The function of this temperature controller will be if temperature is above a pre-set level, cold water will be taken in and temperature lowered. The Spray system is made from stainless steel perforated sheets such that entire width and length is covered by water spray. To prevent water from collecting on the bottles an air knife is placed at the outfeed of the machine, which will blow away the excess water.From the Cooling Tunnel when fresh water is injected into the tank , there will be over flow of the hot water which gets collected in 1200 liter tank  built into the tunnel and  will be circulated by Plate Heat Exchanger and  will bring down the temperature to 35 0  c.  Tunnel will be connected through circulating pump like filling piping water system.We use MCC make plastic chain and matching sprocket in the cooling tunnel. The main body is made entirely from Stainless Steel.

The carbonator consists of a carbonation tank, piston pump, and the electrical panel. The carbonator works on the film flow principle.  A very fine film of liquid is created and allowed to flow over specially contoured film plates. During this flow, liquid is exposed to carbon-dioxide gas at carbonation pressure, and when it reaches the bottom level of the carbonation chamber, it is fully saturated. There is an adjustable nozzle provided on top of the tank by which flow rate can be controlled. A liquid level gauge glass assembly with electronic level control probe is provided. The control panel houses, HP and LP gas regulator with indicator gauges. Complete electric system along with built in alarm system and pressure controller for gas and temperature indicator as one unit. The supply of product from carbonator to filler is by a S.S pipeline.

The bottle is then transferred to the pick and place type screw capper. Here the cap is picked up by the adjustable torque chuck and firmly tightened onto the bottle mouth. The capping chucks are finest quality precision component fitted with magnetic torque controlling coupling. This eliminates heat generation which normally occurs in friction type coupling in the chucks Flexible segmented cap holder picks up the caps. This compensates minor variation in cap diameter occurring due to long storage of caps in boxes. The capping torque can be set between 8 to 16 inch pound with minimum of time and set torque is maintained consistently. The cap delivery chute has a built-in cap washing system. The cap will not be picked up if there is no bottle hence there will be no wastage of caps. The cap delivery is from a hopper based on the ground level making loading of caps easier and also ensures the cap is delivered the right side up to the cap rinsing system. The capping turret is of a pick and place type which delivers the cap to the holder, this leads to improved cap tightening at high speeds. There is a cap rinser in the delivery chute from the hopper to the capping star wheel that insures any contaminants during storage of the cap are removed. The elevator cap hopper is placed on the floor level and so makes material handling and cap loading easier. The chute from hopper to capper has sensors in place to ensure that when the chute is full elevator motor stops. If the caps are not delivered till low level of chute- the machine will stop   and show alarm signal on panel. There is a no bottle- no cap system in place to prevent wastage of caps. There is an ejector mechanism in each capping chuck in case the cap is picked up when there is no bottle.

Glass bottles after recovery from the market require a through and consistent cleaning with detergent and heated water. To fulfill this purpose and ensure highest level of cleaning we supply a Single or Multi Soak bottle washer based on plant capacity and the clients need. The bottle is loaded into the machine by a Positive automatic chain loader which lifts the bottle from conveyor magazine in to the bottle carrier. The Profile of the carrier is designed for smooth handling of the bottles without scouring or scratching them. The bottle first enters into the pre-soak compartment where all the dirt and loose impurity is loosened and removed due to alkali action. The high pressure alkali wash removes all the loose impurities leaving the bottle clean and sterile. The long length provided after final wash allows the bottles to drain, completely before discharging on the conveyor table. Based on capacity and requirement the washing cycle may defer as the number of soaking chambers will change. Synchronized moving Jet mechanism ensures definite cleaning of the bottles. High efficiency steam coils are provided in the tank into heat the water and temperature is controlled by temperature controllers. Rotary type controlled gravity bottles discharge & deliver the washed bottle on the moving conveyor through rotary cam mechanism. The carriers can be easily replaced and snap assembled (without screws) into the chain pockets.

The Beverage processor is an ideal solution for larger capacity plants. The machine mixes water and ready syrup in the required proportion and Pre-Carbonates then further carbonates the beverage thereafter supplying to the filling line. Water and ready syrup are pumped into the mixing tank Mixing will take place either by a stirrer or by a small pump which will have the mix running through the pump continuously. Once filling levels are properly signaled and mixing is over, the mixing transfer pump will switch on and deliver the beverage into the pre carbonation tank, which will be kept at 2.5 kg CO2 gas pressure and will have necessary film plate for carbonation. From the pre carbonation tank a three piston positive displacement pump will take suction and pass the beverage through Plate Heat Exchanger and deliver into the carbonation tank. The carbonation tank will be under 3.5 to 5 kg CO2 gas pressure depending on the product being carbonated. The pre carbonation tank and carbonation tank will have automatic level control switch which will do the interlocking between mix  pump,  pre carbonation pump and carbonation pump. Both tanks will have electrical pressure monitoring transducer which will be regulating CO2 pressure by digital pressure controller.  Pressure adjustment can be done merely by setting the set value on the digital display unit. PHE which is part of the machine will have -4  C  / 40% glycol solution circulation through the cooling side and there will be two temperature sensors, one for monitoring incoming glycol and second for out going chilled beverage.  Both this digital pressure indicators will be connected to the auto and visual alarm.  The beverage temperature controller will be set to control the glycol flow with ON/OFF valve and divert valve operated pneumatically. The complete machine will have necessary air pressure control system with regulators, filters, CO2 filters, and master ON/OFF valves apart from automatic pressure controlling valves. All the original equipments are selected from best manufacturers like Festo, Advance Control System, and Danfoss etc.

To transfer empty plastic bottles to filler air conveyors are used. Atmospheric air is passed through multiple micron filters before being blown by centrifugal pumps into the conveyor's air ducts.

This filling system is ideal for carbonated or aerated beverages like soft drinks, sparkling water or beer. It can also be designed for carbonated beverages with natural fruit pulp content. The Filling valves work on the counter pressure principle, the product is supplied to the filling tank, and the product level in the tank is controlled. The bottles are raised to the filling nozzle by pneumatic lift cylinder, if the bottle is not delivered the valve does not open. The product will be filled to pre set level and the bottle is lowered. The lift cylinders are raised by compressed air and lowered by a positive push cam. The lift cylinders are constantly lubricated by an oil spray thus ensuring a long life cycle and smooth bottle handling. The pressure in the bottle is released after a settling phase via the snifting operation before the bottle is lowered

  At the end of the bottle filling line is the carton packer, erected cartons are packed by a pick and place machine. This machine is suited for high capacity filling lines. Bottles are taken from a single lane conveyor will be distributed into four lane conveyor by a pneumatically operated gate system. The bottles are divided into a desired configuration as per size of bottle and carton. The pick-up head will lower down onto the bottles by a PLC controlled motorized drive. The pneumatic gripper heads will clamp on to the bottle and after a pre set time delay, lift the bottles of the multi chain conveyor. Then the pick-up head will cross over to the carton, once carton is detected it will lower the bottles into the carton.The grip heads are imported from Italy and will operate at very low pressure, and the gripper cups are made of special injection molded PU rubber. The machine has the following interlock safeties: • If power fails and bottles are in the mid air, they will not be released due to PLC control and memory of the grip on position. • If the full grid of bottles 3x4 (or as per specification) is not detected, the system will wait. • On the unscramble table dividing system will operate through pneumatic gate and deliver preset count number of bottles in each lane. • If no carton is detected, system will wait. • The operating system detects any misalignment of bottles or carton while pick-up and placement of bottles into carton.