EXTREME AUTOMATION is one of the leading Manufacturer and Supplier of Automatic Bottling Machineries in our country catering to Breweries, Distilleries and Soft Drinks plants

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EXTREME AUTOMATION is a specialized fully equipped Manufacturing unit Exclusively to Supply of Automatic Bottling Machineries and spares in our country catering to Breweries, Distilleries and Soft Drinks plants up to a capacity of 18,000BPH.

Main Features

1.Stainless steel construction in water line, spray pipes, nozzles, window panels,
Air line, Drain doors, ete.
2.Chain type infeed table for automatic infeed of bottles with nylon sprocket
3. All pumps are horizontal mounting with detachable motors for easy maintenance.
4. Machine body is made out of 8mm and bottom is of 10mm welded boiler grade sheet steel.
5.All curve tracks are provided with support traction rollers mounted on ball bearing shafts.
6. Special clamps for spray pipes.
7. Extra heavy duty gear box.
8.Extra thick front and rear tracks.
9. Hardened and tempered steel pins for main carrier chain.
10. Fully galvanized bucket carriers.
11. Automatic Lable flushing system with brushes at soaking tank.
12. Remote on-off push button stations are provided for operator to operate main drive standing from his place.
13. L.E.D. indications & hooter for fault annunciation.
14. Frequency controlled Vari-speed drive unit is used Vary the main drive motor speed so that we get variable output form machine.
15.Easy to maintain control panel with all safety feature like M.C.Bs. single phasing preventers etc.
16. Digital temperature indicator controls along with air operated valves for accurate temperature control for 65 deg C, 85 deg C and 50 deg C.
17.Automatic regulating type steam injection heating for water zone and steam coil heating for caustic zones.
18.All the suction strainers can be removed without opening the window glass. During operation.
19. Provision for online filteration of caustic.
20.Extra thick bottle carrier chain made of high carbon steel.
21.Auto matic lable flushing system fitted at pre-soak tank with two spray jets.
22. Top covers made of stainless steel.
23. Loading drum curve section made by U.H.M.PE meterial. It will improve lifetime of bottle guides.
24.Plotform are provided on both side for removing spray pipe and easy maintenance.
25.Two set of main shaft with pulling arm assy for effective transmission.
26. Dueplex chain with sprocket are used at loading and unloading mechanism.
27. Maintenance free tracking rollers fitted by roller bearing with water proof seal.
28.Pillow block bearing are used of rear tensioner assy it will improve shaft lifetime and offer maintenance free construction.

Machine Construction

1. MAIN BODY
The main body of the washer is made out of boiler grade 10 mm welded sheet and it rests on adjustable self supported legs. All the components are either welded or bolted.

2. THE DRIVE
The main drive with worm gear reduction is activated by a 3 phase infiintitely variable pulse controlled AC motor to ensure maximum efficiently.

3. BOTTLE INFEED AND OUT FEED
From the supply conveyors the bottles are automatically fed through chain type bottle infeed conveyor to eliminate the manual pushing of the bottles in infeedtable. The bottles pockets fitted to the carrier being self centering to ensure that the bottles are aligned accuratetly as they pass through the machine. In case of failure at the infeed or at the outfeed the drive is delinked automatically.

4. TRANSIMISSON AND ITS TRACK
The sprocket chain in which the bottle carriers are attached provides transmission through a special track. The track is fitted to the side wall of the washer. The carriers are guided slightly above the bottom of the soaking tub to prevent bottles sliding out of carriers.

5. RINSING AND SPRAYING
The rinsing is located at the rear where the bottles are out of the soaking bath. It is two tube high pressure high discharge positive rinsing. The sprays are located at the upper end of the machine with a provision for inside and outside spray of the bottles. It can be seen easy replacement of the spray tubes.

6. PANEL BOARD INSTRUMENTS
The panel board is situated at the front of the machine. The soaklye solution is heated by steam coils to 65 deg C and the spraylye to 85deg C. The temperature is maintained by means of electronic temperature controller. The temperature of the water and lye bath are displayed in the front panel incase of variation in the temperature of the soak lye or the spray lye are 10% than normal it is indicated by the pilot lamp and hooter. The motors of the pumps and the label separator are monitored. The failures are indicated by flash lamps to point out the exact motor failure. The signal continues until the drive is stopped or the motor is rectified.

Operation of the Machine

The bottles are moved by feeding conveyor to the infeed table which moves the bottle to the feed table. From here the bottles are picked up by loading bars and moved in to the carriers horizontally. The bottle carrier chain, the feeding device, the infeed table and the out feed are connected to the main drive by a mechanical system, through the transmission chain the bottles are positioned at the pre spraying device. The dirt and other particles are rinsed out in the pre-soaking zone. This prevents the contamination of the main soaking tank.

After this the bottles are submerged in main soak which further cleans the bottles.
Then the label flushing is done at the rear end of the washer.
Then the bottles passes through the individual spraying zones, where the inner and outer sprayings are performed in the upper section of the machine. The following are the individual spraying zones:

1.85 deg C caustic (12 inner + 4 outer spray)
2.50 deg C hot water (10 inner + 4 outer spray)
3.Room temperature (4 inner + 2 outer spray)
4.Fresh water (4 inner spray)
5.Label flushing spray – 4 Nos. (main sock)
Total No. of sprays – 44 Nos.

Technical Data

01. MODEL : SIGMA – 250
02. TYPE : SIGNLE END HYDRO DOUBLE SOAKING
03. RATED CAPACITY : 15,000-BPH (650ml,325ml)
04. MECHANICAL SPEED : 17,000 BPH
05. ADJUSTING RANGE : 6,000 To 17,000 BPH
06. MAIN DRIVE : Worm gear reduction drive radicon or equivalent pulse controlled AC variable drive
(2 RPM to 12.5 RPM) self braking type motor.
07. TYPE & SIZE OF BOTTLES : Dia: Max 80mm. Min 50 mm. Round shape Ht. Max 335 mm Min 160 mm.
08. BOTTLE RANGE : Dia : Max 80mm. Min 50mm. Round shape : Ht. : Max 335 mm. Min 160 mm.
09. TREATMENT CYCLE:
      Main soaking
      85c detergent rinsing
      50c hot water rinsing
      Normal water rinsing
      Fresh water rinsing
10. TOTAL No. OF BOTTLE CARRIER : 160/24 WIDE
11. PITCH OF THE BOTTLE CARRIER CHAIN: 160mm.
12. DUMPES PER MINIUTE: 10.5.
13. TOAL SOAKING TIME: 8 MIN. At 250 BPM
14. CAUSTIC TREATMENT TIME: 11 MIN. At 250 BPM
15. TOTAL TREAMENT TIME @ 250 BPM 17 MIN
16.STEAM CONSUMPTION : 800 Kg /h at 15,000 BPH Pressure 3.5 Kg C.M.Sq
17.WATER CONSUMPTION : 3 Mtr. 3 /h at 3 Kg Pressure
18. COMPRESSED AIR CONSUMPTION : 25 NM/H
19. WEIGHT : Empty 24 Tons, Service condition 42 Tons.
20. DIMENSIONS
      Length : 12.2 Mtrs. Base : 12.8 Mtrs. (With infeed table)
      Width : 2.7 Mtrs. Base : 3.7 Mrts. (With side plate form and side covers)
      Height : 2.72 Mrts.
21. MACHINE INCLUDING:
      Set of essential spares
      Label flushing system
      Frequency controlled AC speed variator.
      Digital temperature controllers, indicators and pneumatic valves
      Single phasing preventor.
      MCBs for load protection.
      Electric switch board and control panel

Energy Saving features incorporeted in std machine

Power
A.C. Variator is provided for the main drive along with suitable selected gear drive.
High efficient mono block pumps are used for sprays.
All small drives for label remover, conveyor in feed, out feed are by helical reduction gear units.
All 10 h.p motors are with star delta connection to reduce the starting current.

Water
Fresh water sprayed only when the carriers are over the spray jets thus minimizing the fresh water usage. Over flow water from the hot water tank is used for label remover screen blowing. 85deg C caustic solution is drained to the main soaking tank minimizing caustic and water consumption.

Steam
Heating in the main soaking tank, 85deg C caustic spray tank, hot water tank are done by large surface area heating coils for better heat transfer. Bath temps are electronically controlled within + 1degC by pneumatic actuated valves thus avoiding excessive heating. Thermodynamic type steam traps are used along with strainers for efficient use of steam.

Caustic Solution
Provisions given in the discharge of soaker lye pump to divert the caustic solution for regeneration.

Note: Customer has to provide caustic regeneration tank.
Valves are provided to discharge the spray caustic solution to the main soak tank to minimize the caustic usage.

For More Details Feel Free Please Mail Us to info@exatms.com