Here are Some of Our Recent Innovative Engineering Successes

Example #1
Empty Can System Design which eliminates change parts for multiple container heights and diameters
The client requested an empty can delivery system that would allow for a range of empty can heights and diameters with minimal changeover time to be performed by operators rather than line mechanics, and allow for future can size additions with minimal investment.

Traditional design on the empty can system includes a gravity fed twist fitting style air rinser sized specifically for each can diameter, and an airveyor or cable conveyor delivery system with multiple position air cylinder actuated top covers. In addition an Air combiner provides the flow of cans from mass to single file which also requires precise positioning of the top cover for proper can flow.

CTR designed an empty can system utilizing mat conveyors feeding a Zero-pressure combiner, and a single lane vacuum lowerator that carried the can to a vacuum inverting Air nozzle rinser which holds the can by the base. The can path then levels the vacuum chain at the Filler infeed height and transfers the can to a single lane Airveyor for delivery to the Filler infeed metering worm. Design includes the distance calculations from the rinser to the filler for the accumulation and recovery of single file cans to continuously feed the filler despite slight flow variations of the cans from the Zero-Pressure Combiner. Equipment vendors were sourced from the can manufacturing industry as well as traditional soft drink equipment suppliers and integrated for optimum mechanical design and Sequence of Operation. The system has been proven effective for the required quick change features, as well as efficient delivery of cans to the Filler.

Example #2
Modular Syrup Room Process System Design
The client requested an efficient modular design that would be applicable in Greenfield sites as well as retrofit into existing syrup rooms. The standardization of components also required development and adherence to a Clean-By-Design Specification to reduce technician time to keep all internal and external surfaces sanitary. The resulting plan view and P&ID diagram with associated install drawings of the vendor components were integrated into a standard design with modular systems. The operator platform, valve matrix skid, tanks farm, and all associated piping was designed for doubling capacity as the business required the addition of another packaging line or two. Control systems were provided with large backbone and PLC capability, with incremental investment required to double or triple capacity.

Example #3
Heat Recovery of Mold Cooling Process Water
The client requested the heat normally discharged to the atmosphere via the cooling tower exhaust of heat removed from the molds of blow molders be captured and transferred to the water utilized to warm the cold-filled containers.
Through the addition of properly sized and routed supply and return loop piping the recirculating water heated at the discharge of the blow molders is pumped through plate and frame heat exchangers at each warmer to provide BTU transfer to the water sprayed over the cold containers. The process flow was designed to capture the maximum available BTU’s for each warmer and send the water through the cooling tower as a last thermal transfer device thus using available BTU’s first for required warming processes. Steam use has been reduced to start-up and shut-down periods when the heat transfer becomes unbalanced thus saving steam use significantly to heat the water in the warmers.