SubscribeNew branding for the company�s �Carlton Cold� beer involving a new distinctive label has resulted in Foster�s Australia Yatala Brewery(QLD) and Abbotsford Brewery(VIC) upgrading their bottling lines to handle pressure sensitive labels.
With the labels being self-adhesive and of printed clear plastic, the Carlton Cold bottles have to be 100% dry. This is to avoid the risk of moisture entrapment and the formation of unsightly bubbles that would disfigure the new visually appealing label design. Yet the high drying efficiency required must not reduce the original production speed capacity of 1000 bottles/minute with wet glue labels, in fact the goal was ultimately to have an increased capacity.
Initially, Foster's Australia was going to opt for a bottle drying system based upon conventional air nozzle drying technology. However, it was found that to achieve the higher efficiency demanded, a 6-metre long array of multiple air nozzles would be required. The cost and foot print of this option, plus the inherent ongoing maintenance demands and high noise levels, caused Foster's Australia to look for an alternative solution and supplier.
The solution proved to be the 'JetPlate' system from Air Control Industries of Chard, UK, supplied by the company's Australian distributor, Dynamic Engineering Australia, Perth.
According to Andrew Marshall, Manager Packaging Capability, this JetPlate solution, which is housed in an ACI 'LLB' (low level blower) enclosure, costs a third less than the original option considered and occupies around a third of the same foot print - yet fully meets Foster's Australia drying and throughput requirements.
"Performance, safety, space, cost and maintenance are all major considerations when evaluating a new system", said Michael Pecar, Senior Project Engineer at Foster's Australia. "In each respect, the ACI JetPlate is superior to other options considered". His colleague Geoff Gould, Site Services Manager added that he could not understand why anybody would think about buying an air nozzle system when compared to JetPlate, particularly when considering the significant price and performance differences.
ACI's JetPlate features an air delivery system that delivers twice the volume of air than conventional air nozzles, at higher pressure and from a closer position. Also, the entrained air ensures all water and spray is directed downwards to prevent possible recontamination. Further, JetPlates are simple to adjust to suit different bottle sizes with no risk of incorrect positioning and consequent inefficient drying.
Essentially, the JetPlate arrangement comprises facing plenums each with a face plate with stepped air delivery slots. This configuration ensures the air delivery pattern effectively pushes liquid down and off the product as it is conveyed between the plenums. The close proximity of the plenums also ensure there is no risk of bottles falling over.
The JetPlate is both simple to install and maintain because the plenum face plates act as bottle guides thereby eliminating the need for rails. Also, there is no call for pitch adjustment such as might be required with conventional air nozzle systems to achieve optimum drying.
The ACI JetPlate at Foster's Australia also includes the company's optional cap drying system to ensure there is no risk of moisture being trapped under the crown tops.