Even the tiniest flaws affect the overall filling plant capacity. This guide serves you six of the most common culprits plus the way to fight them.
The filling carrousel is spinning and the flow of freshly filled cylinders on the way to your customers is constant. By all accounts, your filling system is running perfectly, so you might not pay that much attention to it.
You should, though. Slowly, but steadily minor flaws invisible to the untrained eye are eating away your profit.
Minor flaw, huge impact
High-capacity filling is all about the output. Carrousel-based filling systems are optimized for maximum performance with all moving parts operating in perfect synch in order to obtain the most efficient production flow. This means that just the slightest delay in an operation can affect the overall plant capacity. And when you fill thousands of cylinders every day, even minor flaws have a huge impact.
Here are some of the problems that our service engineers often observe:
Problem #1: Slow filling head decoupling
Minor flaws in e.g. the filling head decoupling mechanism can cause an already filled cylinder to take an extra round on the carrousel.
The result: An entire round of idle time for the filling machine in question and an overall reduced production capacity.
Problem #2: No signal for decoupled filling head
If the photocell that detects if the filling head has been properly decoupled after filling is dirty or defect, an already filled cylinder might take an extra round on the carrousel.
The result: The same as for problem 1.
Problem #3: Valve malfunction
A valve that closes with just a slight delay immediately impacts the filling accuracy and typically leads to overfilling.
The result: Several tons of gas out the window every year.
Problem #4: Carrousel speed too high
Paradoxically, the filling capacity might decline if the carrousel is spinning too fast. If the carrousel speed does not match the time it takes to fill a cylinder, some of the cylinders may not be full when they have completed a round.
The result: The cylinders in question take an extra turn on the carrousel, most of which will be idle time.
Problem #5: Leak test bottleneck
A leak detector can't begin the test until the gas sensor is clean. If the concentration of gas in the air is too high, the machine will keep trying to clean the sensor head over and over again while the filled cylinders pile up.
The result: bottleneck in the filling line.
Problem #6: Insufficient cleaning and maintenance
A filling system that does not get the care it needs will suffer more from the daily wear and tear and consequently not last for as long as it could have done.
The result: Negative impact on financial results and a need for further investments in equipment.
What to do about it
As you can see, there are plenty of those small profit-eating bugs ready to invade your filling system. The good news is that it doesn't have to be like this.
Carefully cleaning and maintaining your equipment on a daily basis will take you a long way. That's why we always deliver thorough cleaning and maintenance instructions along with our equipment. Take the time to perform the recommended procedures and start seeing the results on your bottom line.
We also offer to take on the task of keeping your filling plant in perfect condition through customized service agreements.