Problem & answerK-19
High or Crooked Caps Not Rejected (or Good Bottles Rejected)
Also covers: Cap height (cap fit) sensor
Likely causes
- Cap height sensor beam not set at the correct cap level for this bottle
- Sensor bracket moved or knocked
- Lens or reflector dirty
- Reject device not working (air, timing)
- Bottle height changed without resetting the sensor
How to fix it
- 1Stop the line.
- 2Segregate bottles since the last successful cap height test and check each cap is fully down and straight.
- 3Clean the sensor lens (and reflector if fitted).
- 4Set the sensor height so its beam passes just above a correctly seated cap: a fully fitted cap does not break the beam, a high or crooked cap does.
- 5Test with a bottle whose cap is deliberately left loose or crooked: it must be rejected.
- 6Test with a correctly capped bottle: it must pass.
- 7Check the reject device removes the bottle.
- 8Record the test and inform QA if faulty bottles may have passed.
Technical note
The cap height sensor confirms every cap is 100% fitted to the bottle. A cap sitting high or tilted breaks the beam and the bottle is rejected before it reaches the induction sealer.It is fixed when
Loose or crooked test cap rejected every time; good bottles pass.
Stop it coming back
- Test the cap height sensor at start-up, after any bottle change or adjustment and at batch end.
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