When less is more

A solution which maximizes the potential of TLM filling technology was devised in close cooperation between a brand-name cosmetics producer and Gerhard Schubert GmbH.

Size variety, filling precision and only half the footprint of conventional filling lines: these are just three of the advantages of the new bottling line, based on TLM technology of Schubert, commissioned by a German cosmetics manufacturer in February 2014.
Two bottling lines needed to be replaced at the production location in question. These lines were capable of filling no more than 30 to 40 bottles per minute. In certain cases, personnel had to be allocated to handle accompanying manual activities such as cap attachment. While converting or cleaning the lines, downtimes of several hours were the norm.

These lines used volumetric dosing systems, which resulted in potentially faulty volume measurement as a result of bubbles, turbulence and air inclusions in the liquid.
Both of the bottling lines also had a large footprint. Their layout was based on a concept which bound individual process steps with backup belts and cycling-in devices. Accessibility to two operating sides had to be taken into account for their installation. Then add to this the long bottle conveyor system based on pucks, i.e. plastic carriers. The pucks have to circulate in a circulation system, which not only requires a lot of space, but makes an enormous amount of noise as well.

With Transmodul: weight, not volume
When it came time to acquire a new bottling line, the brand-name manufacturer contacted Gerhard Schubert GmbH because of the new bottling performance capabilities opened up by the TLM technology from this packaging machine manufacturer.
The patented Transmodul is a single-axis, rail-based robot with exchangeable size plates. Based on these system components, which possess their own intelligence, Schubert created a precise, fast and efficient dosing process. The bottles are weighed on the Transmodul and filled by product weight, i.e. dosing is gravimetric. In February 2014, a TLM bottling line for shampoo, shower gel, lotions and oils was commissioned by the cosmetics manufacturer.

Now, what with a smaller system footprint (around 50% of space saved and without the long conveyor belts crossing the warehouse), the company can also handle a large variety of sizes without a large footprint: oval, round, angular, asymmetrical bottles; upside-down bottles (tottles), which can be turned after filling and capping; 100 to 1,000 ml containers; transparent, semi-transparent and colored plastic bottles (add-on for glass bottles provided). Max flexibility in the choice of caps and closures (screw caps, flip-top caps, snap-on caps, plugs/inserts) and dosing/spray pumps.
The cosmetics manufacturer was also able to cut conversion times in half and has reported very short restart times.
Last but not least, in comparison to the previous solution, the TLM line takes about 30% less time to clean.
The company has reduced its annual consumption of cleaning fluid by about 800 kg and water by around 150,000 liters.

“Less is more” when it comes to bottling cosmetics
Using intelligent control and robots with exchangeable tools, Schubert has achieved a simple mechanical design. This makes the line flexible, enables it to accommodate a great variety of sizes and ensures short conversion times.
Gravimetric dosing saves a considerable amount of product, because it’s very precise. The filling precision across all filling positions is currently between 0.05 and 0.15%, depending on the product being filled. TLM technology enables high-capacity, high-efficiency line solutions. 120 bottles can be output every minute, or in the case of extremely viscous products, 100 bottles per minute. The units do not need to be removed and disassembled in order to clean the line or change the product. The TLM line provides an automatic Clean-In-Place program (CIP).               
 

The TLM bottling system integrates all sub-functions into a single compact line.
Two TLM-F4 robots position lids, pumps and plugs on the size plates of the Transmodule, depending on the program.	The gravimetric filling process: Each individual bottle is weighed while being filled up.
Il processo di riempimento gravimetrico. Le bottiglie vengono pesate singolarmente durante il riempimento.	Once the bottle is capped, the TLM-F2 robot places it on the discharge belt.
In brief, the performances of the TLM bottling lines High overall efficiency One operator console for all sub-functions Requires about 50% less space Filling error under 0.2% (depending on the product and bottle size) Wide variety of bottle shapes and cap types Size conversion: twice as fast as with conventional systems Easy and fast cleaning (CIP) Gentle handling, preserves bottle quality No pucks, low-noise