Troubleshooting Spills and Splashes on a Power Conveyor System

From time to time, we will receive a call from a packager experiencing product spills or even product splashing out of containers during automatic production runs.  This may happen at the beginning of a run, after a changeover or simply occur out of nowhere in the middle of production.  Where product is put in containers in an inconsistent manner, the solution will lie in the filling machine.  When seals on bottles are loose or falling off, the operator will check the capping machine.  But when product is spilling or splashing, there are multiple points on the packaging system that may take fault.

 

Identifying the location of the spill or splash will be the first and best clue as to the cause.  Keeping in mind that the power conveyors - ever moving - will spread the spill or splash throughout the packaging line, the operator should try to identify the original spot of the spill or splash.  In general, if the issue is occurring near a single machine repeatedly, that machine will be the culprit, though on some occasions these issues will occur at more than one location.  For instance, if product is constantly overflowing near the liquid filler, this is the place to start the troubleshooting.  The solution may be as simple as adjusting fill head locations or filling time.  There may be a leak in one or more nozzles that require the replacement of O-rings or other components.  Back pressure from other bottles or improper indexing might also cause a shift in the product, allowing it to splash out of the container.  

 

Similarly, if spills are found near the capping machine, the first point of investigation should be at that machine.  Gripper belts may be too tight, squeezing the bottles as they move through the machine and expelling product before the caps can be properly applied.  Bottles may also be catching on the tongue or the fingers of the cap delivery system, causing a quick tip and pour.  Adjustments to these and/or other components of the capping machine may solve the spilling and splashing issue.

 

Sometimes, however, the spills seem to occur at random points and at random times on the packaging line.  The randomness may be a sign that the conveyor system itself is to blame.  The best bet in this situation is to start at the beginning and ensure that the entire conveyor system is level on the production floor.  The quick movement of the bottles combined with a non-level conveyor may cause spills and bottle tipping.  Second, inspect the belt for any cracks or broken sections.  These literal bumps in the road may also be responsible for tips, spills or even splashes.  Finally, a power conveyor system is usually made up of more than one single conveyor.  Check the transfer sections of the conveyors (where one ends and the next begins) to ensure that bottles are traveling smoothly over these areas and ensure that any dead plates being used have not become warped or broken.

 

In most cases, splashes and spills can be corrected with very little maintenance, most solutions requiring a simple hand adjustment or quick replacement of wear parts.  However, on those rare occasions when bigger problems do rear their ugly heads, LPS technicians are available for more extensive adjustment and repair work.