krones Toptronic

Rotary empty bottle inspector

 Safe inspection, round by round krones Topronic

The Toptronic inspector utilises

state-of-the-art camera technology
to provide precision empty container
inspection. The sophisticated inspec-
tion modules detect even the tiniest
damage or contamination – both
in glass and PET returnable bottles.
Which of the many inspection units
you want to use is entirely up to you.
The KRONES product specialists will
be pleased to assemble a custom
Toptronic tailored precisely to your
product range and inspection require-
ments.
 Figures, data, facts krones Toptronic

Application
9 8 123 4 A, B, C Foreign bottle detection unit
Inspection of empty returnable PET with rejection at the infeed
bottles and empty non-returnable (colour, height, diameter, con-
and returnable glass bottles. tour)
1 Variostation 1 with sealing
Design features surface inspection by camera
2 Base inspection 1 by camera
■ Modular design 3 Variostation 2 with base
■ Table top cover and stand cladding 6 inspection unit 2, full thread
in stainless steel 5 or inner side wall inspection by
■ Safe bottle guidance with Raptec 7 camera
handling parts 4 Variostation 3 with inner side
■ Blower for removing foam and A wall, thread or lateral neck fin-
lubricant residues from the con- B ish inspection by camera
tainer base C 5 Variostation 4 with sealing
■ Enclosed and air-conditioned elec- surface or lateral neck finish
tronics cabinet inspection by camera
■ Electronic function monitoring 6 High-frequency residual caus-
■ Stop function upstream of tic detection
machine infeed in response to 7 Infrared residual liquid detec-
fallen-over containers tion
■ Rejection unit with retaining bar 8 Side wall inspection by camera
or clamping starwheel 9 Optimised scuffing detection
Layout of a fully equipped
Toptronic
Figures, data, facts krones Toptronic

Inspection units

Foreign containers Base 1 Variostation 1: Residual liquid Side wall Optimised Variostation 2: Variostation 3: Variostation 4:
Sealing surface scuffing - Base 2 - Full thread - Sealing surface
- Inner side wall - Lateral neck finish - Lateral neck finish
- Full thread - Inner side wall

Colour sensor P.E. sensor Camera Camera Camera High frequency Camera Camera Camera Camera Camera
+ infrared

Glass Glass Glass Glass Glass Glass Glass Returnable PET Glass Glass Glass
Returnable PET Returnable PET Returnable PET Returnable PET Returnable PET Returnable PET Returnable PET Returnable PET Returnable PET

– – – x x x – – – – –

x Standard
Machine data – Option

Machine output (containers per hour) ** Bottle diameter (mm) * Nominal output up to 72,000 bottles per hour
Glass D** Glass K** PET D** PET K** D** K** ** With rotating bar starwheel (D) or clamping starwheel (K)

68,000 66,000 48,000 < 68 < 63

66,000 64,000 46,000 < 76 < 71
55,000 54,000 43,000 < 92 < 80
49,000 48,000 39,000 < 104 < 94
44,000 36,000 34,000 < 110 < 100
33,000 25,000 26.000 < 110 < 110
 Inspection units 1 krones Toptronic

Foreign container detection unit Base inspection unit

Foreign container detection units CCD camera Base inspection unit In glass bottles, it detects
There are three different systems For detecting the contour, diameter, A camera captures an image of the ■ contamination and damage on the
available for sorting out foreign con- height and colour of glass and return- container base while an LED lamp base
tainers: able PET containers provides uniform illumination of it. ■ foreign objects
The high grey-scale resolution guar- ■ with an additional filter: pieces of
Sensor antees a consistently high image film and glass splinters in the bot-
For detecting the colour of glass con- quality even in containers with differ- tle
tainers ent levels of permeability to light.
In returnable PET containers,
P.E. sensor it detects
For detecting the diameter and ■ contamination and damage on the
height of glass and returnable PET base
containers ■ foreign objects
■ tension cracks on the base
 Inspection units 2 krones Toptronic

Sealing surface inspection unit Infrared residual liquid detection High-frequency residual liquid
detection

Sealing surface inspection unit Checks the neck finish of glass bot- Residual liquid detection unit
A CCD camera checks the container‘s tles for The residual liquid in containers is
neck finish while a dome-shaped ■ Chips detected using two systems which
array of LED illuminate it from below. ■ Cracks operate independently from one
The optionally available Dualflash ■ Wear another:
lighting unit offers even more preci- The infrared system detects all liq-
sion. The newly developed system In returnable PET containers, uids, such as cooking oil, while the
illuminates the neck finish once from it checks high-frequency system specialises in
above and once from below for two ■ The sealing surface for wear and detecting the most minute amounts
camera images. ovality of residual caustic. As a team, these
■ Neck rings for damage and con- two detection systems achieve a
tamination maximum degree of safety.
 Inspection units 3 krones Toptronic

Side wall inspection Scuffing detection for PET

Side wall inspection The module detects Optimised scuffing inspection for
An LED lamp illuminates the entire ■ In glass and returnable PET bot- returnable PET containers
bottle height while two high-defini- tles: wear, dirt, foreign objects and A CCD camera scans the bottle body
tion CCD cameras check the bottles. damage for scratches, illuminated all-round
So that every point on the side wall ■ In glass containers: scuff marks, by an LED lamp. Comparison and sta-
is pictured once from the front, the large-area chips and (with an addi- tistical evaluation are employed to
bottle rotates on the container table. tional filter) pieces of film analyse the degree of impairment. So
The cameras capture multiple images as not to impair the result, factors
of each bottle. This means top results such as droplets of water are masked
are achieved even with problematic out by digital filters.
bottles, such as bottles with textured
glass or ice-covered bottles.
 Inspection units 4 krones Toptronic

Variostations
Depending on application and Top-
tronic model, the Variostations can
be “topped-up” with various modules

Full thread inspection unit Lateral neck finish inspection unit

Full thread inspection unit Inner side wall inspection unit Lateral neck finish inspection unit
■ Detects damage on the screw ■ Uses a CCD camera to inspect the ■ Checks the neck finish of crown-
thread of glass containers inside of the container through its sealed bottles for contamination,
■ Detects dirt contamination on the opening rust deposits, cracks and chips
screw threads of MW-PET contain- ■ Detects dirt on the inner side wall ■ Detects dirt contamination on the
ers ■ This means that it inspects the caps of MW-PET containers
■ Illuminates the containers with a inner side wall precisely, even if ■ Illuminates the sealing surface
stroboscope lamp there is a large-area ACL label on from above using a dome-shaped
■ Uses a CCD camera and special the container array of LEDs
optical components to record an ■ Uses a CCD camera and special
image of the entire screw thread optical components to record an
all-around picture of the neck fin-
ish
Operation and change-over krones Toptronic

Teleservice

■ An authorised person with a

PC which is installed above the
inspector can dial into the KRONES
network via a telephone line or
Internet/VPN.
■ Monitoring and operation of the
inspector via teleservice, display of
all parameters and camera images
■ Optimisation of the inspection
units, retrofitting for new contain-
er types
■ Quick fault diagnostics
■ Shorter downtimes and fewer
on-site service calls thanks to the
24-hour teleservice availability
■ Practical training possible via tele-
Screen Documentation service

■ 15 inch touch-screen ■ Recording of all relevant operating

■ Display of all relevant operating and production data, e.g. changes
data including a rejection trend to parameters and results of the
analysis with display of all camera test-container program
images ■ Saving of all data with informa-
■ Operation and adjustments via tion regarding the times and
individual access levels with user- operator names
defined transponders ■ Possibility to transfer defined
operating data to an operating
data acquisition system (Weihen-
stephan protocol), to the custom-
er’s network, or to the customer‘s
PC
 Operation and change-over krones Toptronic

Test bottle programme Type change Raptec guidance handling parts

With the Raptec guidance handling
■ Semi-automatic function monitor- The high degree of automation parts, downtimes on product change-
ing at regular intervals, as well as makes format changing very easy: over can be dramatically reduced.
each time the machine is switched Special quick-locks and the light
on and when it is changed over to ■ Once a new container type has weight mean the work is done quick-
a new container type been selected on the touch-screen, ly and easily, cutting change-over
■ A prepared assortment of test con- the container parameters are times by as much as 30 %. Thanks
tainers can be conveyed through changed automatically. to their open design, the guide star-
the machine in any order ■ In the event of differences in con- wheels and curved guides are also
■ The faults included on the test tainer diameter, the infeed worm, very easy to clean.
containers are used to test if the curved guides and starwheels
individual inspection units are are replaced. The change-over is Guide starwheel
working properly. quick and easy, taking just a few Quick-lock with one hand
■ Results are saved and displayed. minutes, as all handling parts
■ The data can be transferred to the are uniquely colour-coded and Curved guide and guide rail
operating data acquisition system, numbered. Curved guides and ■ Centring sensor for easy position-
to a network, or to a printer starwheels are secured by captive- ing of parts
type quick-release fastenings. ■ Guide rail divided into handy units
■ The machine head with the cam- ■ Optional: pneumatic clamp oper-
era carrier plates is adjusted to ated from the Toptronic touch-
the new bottle height by a semi- screen
automated mechanism.

Raptec
handling parts
 Additional equipment krones Toptronic

■ Special filter for detecting glass

fragments and pieces of film with
the base inspection unit
■ Special filter for detecting pieces
of film with the side wall inspec-
tion unit
■ Dualflash lighting system for
inspecting the sealing surface of
glass containers
■ Electronic bloc connection with
the filler
■ Uninterruptible power supply unit
■ Machine network connection and
remote visualisation
■ Printer
■ Transponder for test container
programme
■ Container pool statistics

Raptec
handling parts
 Your benefits krones Toptronic

■ Modular design ■ Adaptability

There is a range of different As the discharge conveyors can be
inspection modules and detection configured at will, the inspector
systems available for the Top- can also be easily integrated into
tronic. You can work together with existing lines.
our product specialists to select
precisely which of the options you ■ Precise container guidance
wish to use. Should your inspec- The bottles are safely guided
tion requirements change at a through the machine by the
later date, the machine can be handling parts, so enabling high-
simply equipped with additional precision inspection.
modules.
■ Upright rejection
■ Quick type change-over The rotating bar and clamping
To reduce the operator‘s work starwheels permit safe upright
load, a major part of the adjust- rejection of the containers.
ment and conversion work is auto-
mated. And the Raptec guidance ■ Uniform operating concept
handling parts even cut change- All KRONES machines are
over times to pit-stop duration! equipped with a uniform operat-
ing concept for maximum user-
friendliness.

Sidewall
inspection
 krones Toptronic

Contact LCS Lifecycle Service TCO Total Cost enviro

T C O of Ownership
Visit by a customer consultant
Further information material
Each company, each facility, is unique. The client is the paramount focus krones stands for innovative ma-
By making the appropriate selection of krones’ product strategy. This is chines and high-performance lines.
Mr Ms from the capabilities offered by LCS why many of our new ideas emerge enviro epitomises its commitment to
Services and LCS Parts + Software, from close liaison between our ser- saving costs, by reducing energy con-
Subject to technical changes · The illustrations can contain optional auxiliary equipment. · 0 900 22 838 0 · PDF_e · 06/09

you will receive a package tailored vice and sales people and the client sumption and ensuring economical
First name precisely to your actual needs. And in on site. The R&D departments at use of natural resources. Intelligent
addition, you benefit from our com- krones then develop the appropri- machinery design to a maximised
prehensive expertise gained from op- ate products, geared without excep- level of technical excellence enables
Surname
erating production lines in the food tion to cutting our clients’ operating us to grant exceptionally long life-
and beverage industries, and in the and raw-material costs (total cost of times and economical efficiency to
Company cosmetic, chemical and pharmaceuti- ownership). optimised ergonomics and safety for
cal sectors as well. the operators and the maintenance
staff alike.
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