On-demand filling – the road to super-flexible production
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In order to redefine the boundaries of flexibility, Krones initiated the concept study of “on-demand filling”.
“On-demand filling” represents a super-flexible production line that can be perfectly transformed with the push of a button:
Different filling methods
Personalized decoration
Carrying a personal RFID chip
Form a mixing tray directly in the production line
Personalized filling without dressing
The core element is a newly developed filling valve. It presses the bottle against the valve and the filling liquid flows down the wall of the bottle. So far, everything is still a regular step. The difference between this filling valve and other filling valves is their extraordinary diversity. It gets the filling liquid through a main pipe and up to four auxiliary pipes, each of which can be fed separately. Depending on the application of the filling machine, three completely different advantages can be brought:
No mixing machine
Soft drinks and other mixed beverages can be prepared directly in the filling machine: water enters the filling valve through the main pipe, and each flavor component is fed through the secondary pipe at a suitable flow rate. Therefore, it is no longer necessary to carry out the beverage mixing in the front mixer, and only the necessary pretreatment of the water and flavor components is required.
Product conversion does not need to be changed
Similarly, different finished syrups can be fed through the secondary tubes of the valve. In this way, different fillings can be accessed and closed without the need for a changeover. There is no longer a need for a cumbersome flushing process because the main channel flows in water regardless of the production of any product. The syrup flows into the machine through a separate line until it is added before filling. The new filling valve is equipped with a unique sealing method that completely eliminates the risk of odor.
Recipe customization
For all users who want to personalize their products to the limit, the system also has another option: a personalized combination of different inclusions – which allows for a true 1 lot. In this way, different components can be prepared through the secondary tube of the filling valve, and the precise beverage component can be determined individually for each bottle. “We are here mainly targeting high-end products and luxury products for branded goods manufacturers,” explains Stefan Pöschl, head of technology development at Krones. “For example, the formula for sports drinks and medical drinks is precisely adjusted according to the needs and preferences of consumers.”
There is no problem with the obligation to inform the inclusion of substances: what kind of formula the consumer ultimately takes in his hand can be marked on each bottle by direct printing.
Mixing trays do not need to be shipped separately
How to implement the “on-demand filling” principle in a set of filling equipment requires consideration of many factors, especially the characteristics of each company. The conceptual study of the field test at this exhibition follows the principle of maximum flexibility and includes the following:
a filling station
a direct print module
Highly flexible conveyor system
Radio frequency identification chip tracking system and identification container
Access order system, which can personalize the filling product and appearance of each container.
“On-demand filling” can produce a large number of different products in one production line – in the smallest batch and fast alternating sequence. By combining a corresponding set of dry zone equipment, the scope of application can be increased by the option of forming a mixing pallet directly on the production line and then delivering it immediately – no warehousing is required and no picking is required.
Developer's words
“Bottling on Demand demonstrates what we can achieve in a future filling line: future equipment can not only significantly reduce existing dressing times, but also based on direct printing and flexible filling valves. It can even be converted into a content product without transition. In this way, the mixing tray can be produced directly in the filling line according to the purchasing habits of the end user. In the beverage industry, we will embrace a more anticipated era. Just filling new on demand. The space for the development of the transport is unpredictable, but we can clearly see that it has the potential for change and will certainly occupy an important position in the stand-alone field.” Klaus Voth, Electromechanical Technology Development
“As digital technology continues to evolve, consumer buying behavior will change: ordering personalized products through application software will become an important part of everyday life, and this will accelerate the pace of business processes. The result is a set of modern equipment. With on-demand filling, the newly developed solution not only meets the individual needs, but also responds quickly to customer needs – nevertheless, the overall production requirements remain efficient. Andreas Gschrey, Digital and Data Technology, Enterprise R&D Center
“The on-demand principle is also reflected in the data flow. Unlike traditional equipment, the data here is not determined in advance, but is generated when needed. Since each bottle contains a personal RF tag, all goods can be Clear identification. Results: High product safety through seamless tracking – from the beginning of beverage production, through logistics to retail outlets. For marketing, RF tags also offer some potential because it can carry Some of the information that is important to the end customer. It is the personalization of this product that will have a huge impact on healthy drinks or sports cocktails from special groups in the future."
Jennifer Schöffel, Monitoring Technology, Enterprise R&D Center
“As our solution justification report points out, market- and demand-driven production is no longer a dream. On the contrary: the process technology implied by on-demand filling is the production plan for users of beverage production lines. Providing a huge free space: even JIT filling can be achieved in high-speed equipment. Throughout the existing process and development trends, this concept will clearly show a way forward."Stefan Pöschl, Process Management