Common Faults and Maintenance of Packaging Production Lines (Taking Beer Packaging Line as an Example)

As a packaging machinery parts supplier specializing in tobacco packaging machines, Hansheng Automation offers gear manufacturing capabilities of ISO Class 5 (module 0.1-5.0, diameter 3-300mm), CNC machining accuracy of ±0.002mm (super-mirror finish), and casting tolerance of ±0.03mm (maximum machining size is 3800*1500*1200).We have successfully provided solutions for the customization and production of packaging machinery in Vietnam

At the final stage of beer production, the stable operation of the packaging line is directly related to product quality, production efficiency, and company costs. From bottle washing and filling to sterilization and labeling, equipment failure at any stage can cause production line downtime and result in unnecessary losses. This article will detail common faults and solutions for the four core pieces of equipment in beer packaging lines, and share practical maintenance tips.

The bottle washer is the first "checkpoint" in beer packaging. Its primary purpose is to remove stains, residual labels, and bacteria from bottles, providing clean containers for subsequent filling. However, during continuous operation, bottle washers often experience various problems due to improper operation or component wear.

Common Problems and Quick Solutions

Bottle infeed/outfeed misalignment: This is one of the most common problems, often caused by a misalignment between the chain and clutch. This can be resolved by adjusting the position of the clutch's mounting bolts or calibrating the chain's and clutch's synchronization.

Bottles stuck in the bottle box: If a bottle is stuck in the bottle box, first check for broken glass or other debris and clean it immediately. If the bottle box is damaged or the bottle pusher is worn, replace the corresponding parts.

Slow heating in the lye tank: Insufficient steam pressure, condensate in the pipes, or a clogged heat exchanger can all cause slow heating. Increase the steam pressure and drain the condensate. If the problem persists, disassemble the heat exchanger and clean the surrounding dirt.

Bottles falling off the bottom or rotting: The former is often caused by a large temperature difference between the lye tank and the hot water tank, which needs to be reduced. The latter may be caused by misalignment in the bottle infeed position or a damaged bottle box. Adjust the infeed position or repair the bottle box.

Daily Maintenance Key Points

Clean broken glass and residual labels from the bottle racks and bottle hopper daily, and ensure that the spray pipes and filter screens are not clogged.

Regularly scrub the alkali tank thoroughly, allowing the alkali solution to settle in a temporary storage tank, and then rinse the tank thoroughly. During overhauls, manually descale the alkali tank and heater.

Keep the chain path and entrance and exit areas clean, and promptly remove broken glass and accumulated water around the machine to prevent secondary contamination.

The filling machine is a key piece of equipment that determines the taste and quality of beer. Its core mission is to ensure accurate filling volume and a tight seal. Failure can lead to problems such as leaks and insufficient vacuum, impacting product quality.

Common Faults and Solutions

Bottle Leaks and Poor Seals: If you notice wine leaking from a bottle, first check whether the air pressure is within the specified range or whether the bottle support cylinder is leaking. If the valve frame is tilted or the bottle support plate is worn, replace the calibrated valve frame or a new bottle support plate.

The wine valve is empty or half-filled: This could be due to a probe grounding issue, a damaged solenoid valve, or a deteriorating wine valve gasket. Adjust the probe position and replace a damaged solenoid valve or gasket. Also, check that the bottle meets the specified specifications.

Wine Backflow or Insufficient Liquid Level: Incomplete pressure relief is the primary cause. Replace the worn pressure relief slide or valve stem. If the wine temperature is too high or the CO₂ content is too high, reduce the wine temperature and CO₂ concentration to stabilize the back pressure and wine pressure in the wine tank.

Insufficient vacuum: A lack of water in the vacuum pump, leaks in the pipe joints, or a worn vacuum slide can cause insufficient vacuum. This can be resolved by increasing the water injection volume, sealing the pipe joints, or replacing the vacuum slide.

Key Maintenance Tips

After daily production, flush the equipment with hot water (rinsing away residual wine first) and clean any wine residue and broken glass from the bottle support cylinder.

Regularly clean the filter drain screen, check the oil levels in the gearbox and worm gearbox, and drain condensate and sediment promptly.

After equipment has been idle for more than three days or after completing a process cycle, perform a CIP cleanup with hot caustic soda to ensure that the pipes and wine tanks are free of residue.

A sterilizer uses high temperatures to kill microorganisms in beer, and its operating status directly affects the shelf life of beer. Incomplete sterilization or improper temperature control can lead to beer spoilage and bottle breakage.

Common Faults and Solutions

Slow Sterilization Tank Temperature Increase: Low steam pressure, insufficient pipe flow, or a clogged heat exchanger are the main causes. Increase steam pressure, replace pipes with larger diameters, or clean alkaline and scale deposits in the heat exchanger.

High Breakage Rate of Semi-Finished Beer/Bottles: If bottles frequently break, check the pressure capacity of the bottles and replace unqualified bottles. Reduce filling pressure to avoid excessive pressure inside the bottles. If the temperature zones fluctuate significantly, inspect the pneumatic diaphragm valve for leaks.

Abnormal PU Value: The PU value is a key indicator of sterilization effectiveness. If the PU value is too high, lower the temperature in the fourth and fifth zones. If the PU value is too low, check the steam pressure and spray pressure and clear any clogged nozzles.

Maintenance and Calibration Tips

Promptly clean broken bottles from the inlet and outlet and chains. Remove glass fragments from the machine during downtime to avoid scratching the equipment.

Regularly clean the spray pipes. After production, rinse the chain plates and screens with high-pressure water to remove organic contaminants.

Clean the interior of the sterilizer daily and check the spray nozzles for blockage. Calibrate the instruments regularly, test the sterilization intensity every cycle, and adjust the parameters based on the results.

Labeling machines apply labels to beer bottles. The smoothness and alignment of labels directly impact the product's market image. During operation, problems such as tearing, skewing, or falling labels require prompt attention.

Common Faults and Adjustment Methods

Torn Labels During Label Removal: Labels can tear when the label clamp is positioned too far forward or the drum track is misaligned. Adjust the label clamp position backward to align the drum pulley track. If the label is too brittle, replace it with a qualified label.

Skewing or warping labels: Label box height deviation, incorrect drum position, or worn labeling sponge are the main causes. Adjust the left and right height of the label box, correct the drum position, and replace any worn sponges. Also, adjust the distance between the label brush and the bottle.

Label Shedding: Improper adhesive dosage or temperature can cause label shedding. Select the appropriate film thickness and maintain the glue temperature within a reasonable range.

Cleaning and Lubrication Tips

Use hot water no higher than 40°C to clean the marking plate, rubber roller, squeegee, and other components to prevent high temperatures from damaging the equipment. Avoid using sharp objects when cleaning residual glue from the marking station to prevent scratching the surface.

After cleaning, use compressed air to blow out any remaining water from the brush and drum. Rinse the marking glue pump and drum with clean water to remove any residual glue.

Regularly lubricate components such as the marking bin bearings, drum cam, and bottle press head to maintain smooth operation.

Establish a fault database: Record the equipment, time, cause, and resolution of each fault. Through data analysis, identify frequent fault points (e.g., bottle misalignment in the bottle washer, aging gaskets in the filler), and develop targeted preventive plans.

A tiered maintenance system: Daily maintenance (daily cleaning and inspection) is performed by operators; scheduled maintenance (weekly calibration, monthly component replacement) is performed by maintenance personnel; and advanced maintenance (quarterly overhauls, annual calibration) is performed in collaboration with the equipment manufacturer to ensure professionalism.

Spare parts safety stock: Maintain a stock of 3-5 sets of consumable parts (e.g., gaskets, brushes, nozzles), and one set of critical components (e.g., drums, valve frames) to avoid extended downtime due to waiting for spare parts.

The efficient operation of the beer packaging production line is inseparable from the stable operation and maintenance of these four major equipment. I hope this article about the common problems and maintenance suggestions of the four major equipment of the beer packaging production line can help you.