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Bottling Line troubleshooting · Ask Dhanu

MachinesBottling Line

Bottling Line

Operations and troubleshooting for capsule, tablet and gummy bottling lines — bottle feeding, counting and filling, desiccant insertion, capping, induction sealing, printing and labelling, metal detection and checkweighing.

All problems as a list90 problems53 guides

Problems & answers

Printing & Labelling21
Bottle Feeding & Conveyors15
Desiccant Inserter7
Counting & Filling11
Capping19
Induction Sealing8
Metal Detection & Checkweighing4
Electrical, Utilities & GMP Events5

Guides & procedures

Introduction1
Safety, Hygiene & PPE4
Line Overview2
Reference Machine Settings6
Line Operation Procedure12
Machine Operation & Checks13
Quick Fault Finder1
Cleaning & Status Labels3
Packaging GMP & Documentation7

Problems & answers

P

Printing & Labelling

Printer Not Printing or Poor Print QualityP-011 photoPrinter offline or wrong message selected · Low ink or ribbon · Dirty print head Half Print or Part of the Code MissingP-02Also: Ribbon not straight or misalignedRibbon running at an angle (not straight) across the print head · Ribbon shifted sideways so it does not cover the full print area · Guide rollers out of line or the adjuster moved

Typical Cap Application Torque

1

Line Clearance Checklist1

Start-Up Sensor & Safety Test Checklist1

No PrintP-03Also: Ribbon printerRibbon run out or broken · Ribbon loaded the wrong way (ink side away from the product) · Print temperature or energy too low

Faint, Patchy or Broken CharactersP-04Temperature or energy too low · Print head dirty · Print pressure low

Ribbon Wrinkling or CreasingP-05Ribbon not straight on the rollers · Uneven or low tension · Guide rollers not parallel

Ribbon Breaking or TearingP-06Tension too high · Temperature too high (ribbon burns through) · Sharp edge or burr on a roller

Ribbon Wasted or Advancing Too FarP-07Ribbon advance length set too long · Ribbon save mode off · Take-up slipping

Wrong Batch Number or Dates PrintedP-081 photoAlso: CriticalMessage not updated at changeover · Data entered incorrectly · Printer clock wrong

Labels Not Applying, Skewed or WrinkledP-09Label web tension incorrect · Label sensor not taught to the label gap · Applicator speed not matched to conveyor

Missing or Wrong LabelsP-10Splice or missing label on reel · Wrong label reel loaded · Label verification not working

Print in the Wrong Position on the BottleP-11Also: Printer and side-grip conveyor not alignedPrinter head height not set to the print area at the bottle bottom · Side-grip belts holding the bottle too high or too low · Ribbon not centred on the print head (see P-02)

Bottles Damaged or Stuck in the Side-Grip BeltsP-12Also: Belts too tightBelt gap set too narrow (grip too tight) · Belts not parallel · Belt speeds unequal (bottle twisted)

Bottles Dropping from the Side-Grip ConveyorP-13Also: Belts too looseBelt gap too wide · Belt worn or stretched · Width knob loosened by vibration

Side-Grip Belt Misaligned, Riding Up or Coming OffP-14Also: Belt re-fitting procedureLong use: belt stretched or worn · Roller (pulley) not square or loose · Belt tension uneven

Bottle Twisting or Skewed PrintP-15Also: Side belts at different speedsLeft and right belt motors set to different speeds · One motor faulty or slipping

Inkjet Code Too Far Left or Right on the BottleP-161 photoPrint position (delay) not set for this bottle · Product detection sensor moved · Conveyor speed changed

Inkjet Code Too Large or Too SmallP-171 photoScale (width) setting wrong for the bottle or label · Wrong job selected

Print Count Does Not Match Product CountP-18Also: Missed printsProduct detection sensor missing bottles (dirty, misaligned) · Bottles too close together · Printer paused or faulted during the run

Ink or Make-Up Low WarningP-191 photoInk or make-up fluid cartridge nearly empty

Inkjet Print Broken, Scattered or BlurredP-20Print head dirty (ink build-up) · Print head too far from the bottle · Nozzle partly blocked

Printer Not Running (Will Not Start or Stops)P-211 photoPrinter stopped or paused · Jet start-up fault or blocked nozzle · Fluid empty

F

Bottle Feeding & Conveyors

Unscrambler / Bottle Feeder Not Feeding BottlesF-011 photoBottle jam in the hopper, disc or outfeed · Bottles loaded incorrectly or hopper empty · Guide rails not set for the bottle size Bottles Falling Over or Not UprightF-02Bottle blow time or blow delay incorrect · Conveyor speed mismatch between sections · Guide rails too wide Side Belt Slipping / Bottles Not Moving SmoothlyF-03Loose belt tension · Belts not parallel · Worn or contaminated belt Bottle Jam Alarm on the ConveyorF-04Damaged or deformed bottle · Downstream machine stopped · Jam time or delay setting too short Bottles Stuck or Not Moving ForwardF-05Also: Guide rails too tightGuide rails set too narrow for the bottle · Rails not parallel (narrowing along the conveyor) · Rails set at the wrong height (catching the shoulder or neck)Bottles Bunching or Blocking 2–3 AbreastF-06Also: Guide rails too looseGuide rails set too wide · Rail clamp loosened by vibration · Too many bottles released by the feeder (stop sensor fault)Bottle Stop Sensor Not WorkingF-07Also: Feeder keeps sending bottles · bottles crushedSensor lens dirty or dusty · Sensor knocked out of alignment or bracket loose · Sensing distance or sensitivity wrong for the bottle Bottles Tipping or Gapping at a Conveyor TransferF-08Also: Belt speeds not matchedDownstream conveyor slower than upstream (bottles pile up) · Downstream conveyor much faster (bottles tip or gaps open) · Transfer plate or belt ends not level Wrong-Way Bottles Passing to the LineF-091 photoAlso: Orientation reject sensor not workingOrientation (wrong-way) sensor dirty or misaligned · Sensor bracket moved during cleaning · Air blow-back not firing: low air pressure, blocked nozzle or solenoid fault Good Bottles Being Blown BackF-101 photoAlso: False rejects at the unscramblerSensor position or sensitivity wrong for the bottle · Blow delay too long or too short (blast hits the next bottle) · Bottles touching or too close together Bottle Stuck at the Unscrambler OutletF-111 photoAlso: Pocket wheel blocked · machine stopsThe two outlet guide plates (aluminium guides) not aligned with the pocket wheel · Guide gap too narrow or too wide for the bottle · Guide plate fixing screws loose Unscrambler Bowl Overfilled with BottlesF-12Also: Hopper level (bowl full) sensor not workingBowl level sensor dirty or dusty · Sensitivity set wrong (does not see white bottles, or sees the far wall) · Sensor bracket moved or aimed at the wrong level Bulk Bottle Feeder Conveyor Not RunningF-13Also: Green cleated feeder · no bottles into the bowlA bottle stuck at the bottom of the bulk hopper where the belt picks up (main cause), or between cleats, at the chute or the drop into the bowl · Bulk hopper overfilled, so bottles press on the belt and wedge · Bowl level sensor dirty, misaligned or faulty (feeder thinks the bowl is full)Product Lifter Not Lifting ProductF-14Safety door open or door sensor misaligned · Product blockage in the bucket or chute · Level sensor misaligned Counter Hopper Running Empty or OverflowingF-15Also: Main hopper level sensor (product add sensor)Main hopper level sensor dirty (product dust or sugar coating on the lens) · Sensor sensitivity or position wrong for the product · Sensor bracket moved

D

Desiccant Inserter

Desiccant Cutting in the Wrong PlaceD-011 photoAlso: Cutting sensor red spot not on the cut pointCutting position sensor moved, so its red light spot is no longer on the cut point (main cause) · Sensor knob or bracket loosened by vibration or cleaning · Sensor lens dirty Desiccant Missing from BottlesD-021 photoReel empty or broken · Bottle not detected · Insertion tube blocked Double Desiccant or Wrong LengthD-03Sensor misaligned · Sachet pitch varies on the reel · Feed motor overrun Desiccant Jamming in the FeedD-041 photoReel tension incorrect · Guides misaligned · Damp or swollen sachets Desiccant Not Pushed Down or Sticking at the Feed RollersD-051 photoAlso: Feed roller pressureFeed (pinch) rollers too loose: the strip slips and is not pushed down to the cutter · Feed rollers too tight: the strip sticks, creases or tears · Rollers dirty with silica dust Cutter Blade Not Cutting FullyD-061 photoAlso: Sachets still joined or cut on one side onlyCutter blade position out of adjustment · Blade uneven: tight on one side, loose on the other · Blade blunt or chipped Desiccant Falling Outside the BottleD-071 photoAlso: Bottle not centred under the cutter funnelBottle mouth not centred under the small funnel / cutter release point · Small funnel moved or its fixings loose · Bottle stopping in the wrong position (bottle stop or delay)

N

Counting & Filling

Incorrect CountN-01Also: Over- or under-countVibrator speed too high (product overlapping) or uneven · Counting sensors dusty or dirty · Area limits (min/max) not set for the product Product Jamming in the ChannelsN-021 photoVibrator speed too high · Channels dirty or sticky · Gummies soft or sticky (heat or humidity)Low OutputN-03Vibrator speed too low · Hopper level low · Uneven product flow No Bottle Alarm at the CounterN-041 photoBottle sensor dirty or misaligned · Bottles not reaching the fill position · Upstream feeder stopped Product Missing the Bottle / SpillingN-05Also: Funnel not centred over the bottleFunnel outlet not centred over the bottle neck (main cause) · Funnel moved during cleaning or its four black knobs loose · Bottle stopping in the wrong position (bottle stop or change delay)Broken or Damaged Product in BottlesN-06Vibration too aggressive · Drop height too high · Product brittle (low humidity) or soft (high humidity)Vibratory Tray Not Vibrating or Making a Loud Banging NoiseN-071 photoAlso: Tray fixing screws looseTray fixing screws loose, so the tray is not clamped to the vibrator drive (main cause) · Tray not seated correctly after cleaning · Vibrator amplitude set too high Uneven Flow Between Vibratory TraysN-081 photoAlso: Product piling at tray junctions or gaps in flowVibration settings not tuned for the product (each tray needs its own value) · Vibrator start delays incorrect · A tray set too slow for the product arriving from the tray before it Product Sticking in the Collecting Chute or FunnelN-09Also: Short count followed by over-countGummies sticking to the chute or funnel walls (sugar, oil, heat or humidity) · Chute or funnel misaligned after cleaning · Chute fixing knobs loose, so the chute has moved Counting Head Error or One Head Not CountingN-10Sensor cable connector loose or not fully latched · Cable damaged or pinched · Counting sensors dirty Counter Dropping Product with No BottleN-111 photoAlso: Bottle presence sensor not workingBottle presence sensor dirty, misaligned or bracket moved, so it signals a bottle that is not there · Sensor seeing the guide rail or conveyor instead of the bottle · Sensitivity set wrong

K

Capping

Caps Not FeedingK-01Also: Cap lifter / chute blockageCap hopper empty · Cap lifter angle incorrect · Jam in the lifter or chute Caps Crooked or Cross-ThreadedK-02Bottle not centred under the capping head · Guide rails misaligned · Capping head height incorrect Loose Caps / Torque Too LowK-03Torque setting too low · Worn spindle wheels, rollers or clutch · Cap speed too low Caps Over-Tight, Stripped or CrackedK-04Torque setting too high · Cap speed too high · Head height too low Bottles Jamming at the CapperK-05Bottle separation delay incorrect · Conveyor and machine speed mismatch · Guide rails too tight Scuffed or Marked CapsK-06Worn or dirty capping wheels · Excessive wheel pressure · Cap speed too high Cap Elevator Not Running or Caps Not LiftingK-07Also: Caps blocking the bottom of the cap hopperCaps (including caps returned from the chute) wedged at the bottom of the hopper where the elevator belt picks up (main cause) · Hopper overfilled so caps press on the belt · Cap level sensor in the chute signalling full Caps Jamming in the Elevator or SelectorK-08Also: Steel selector plates not set for the capSteel selector (orientation) plates not set to the cap height for this bottle · Cap size changed (e.g. 120 cc and 150 cc bottle caps differ in height) without resetting the plates · Plate fixing screws loose Caps Blocking or Dropping Out at the Chute GuardK-09Also: Plastic cap guard not set for the cap heightClear plastic guard at the elevator outlet / cap chute set too tight for the cap height: caps block · Guard set too loose: caps tip and drop out of the chute · Guard black knobs loosened by vibration Bottles Leaving the Capper Without CapsK-101 photoAlso: Cap chute sensor not workingBlue cap sensor on the cap chute dirty or misaligned · Sensor sensitivity wrong for the cap colour or material · Sensor bracket moved Caps Stuck in the Curved Cap ChuteK-111 photoAlso: Chute cover plate too tightCover plate over the cap chute set too tight (caps cannot slide down by gravity) · Cover plate too loose (caps ride up, turn over or jam) · Plate not parallel to the chute Bottles Not Held Straight at the Capping HeadK-121 photoAlso: Blue bottle-holding beltsBlue bottle-holding (side grip) belts too loose: bottles lean or turn · Belts too tight: bottles squeezed, stopped or deformed · Left and right belt speeds not equal: bottles twist Caps Not Placed on the BottleK-131 photoAlso: Cap placement plates set too tight or touching the capsCap placement plates at the chute outlet set too low or too tight, so the plates press on the caps · Plates not centred over the bottle path (left / right) · Capping head height wrong for the bottle Caps Blocked at the Bottom of the ChuteK-142 photosAlso: Cap release spring too tight · bottles leaving without capsSpring on the cap release (escapement) at the bottom of the chute too tight · Release screws set so there is no space between the cap and the parts · Cap size changed without resetting the release Cap Pusher Not WorkingK-151 photoAlso: Caps not pushed down onto the bottleLow air pressure · Pusher cylinder or valve fault · Pusher timing incorrect Caps Not Tightened Evenly by the Capping WheelsK-16Also: Four capping wheels each side not set correctlyOne or more of the four capping wheels set too wide (cap not gripped: loose caps) · Wheels set too tight (caps over-tightened, scuffed or cracked; bottles stopped) · Left-side and right-side wheels set differently Caps Not Fully Seated After CappingK-17Also: Spring-loaded hold-down plate not set for the bottleHold-down plate set too high for the bottle: it does not press the cap down · Plate set too low or springs too tight: bottles jam or caps are crushed · Plate not moving freely up and down (springs dirty, bent or binding)Bottles Entering the Capper Without Caps or Moving Too SlowlyK-18Also: Capper infeed (stop) wheelInfeed wheel not stopping when the cap sensor signals no caps (sensor or wheel fault), so bottles pass uncapped · Infeed wheel speed set too slow: bottles crawl through the capper and output drops · Infeed wheel speed too fast for the cap feed: caps missed High or Crooked Caps Not Rejected (or Good Bottles Rejected)K-19Also: Cap height (cap fit) sensorCap height sensor beam not set at the correct cap level for this bottle · Sensor bracket moved or knocked · Lens or reflector dirty

I

Induction Sealing

Seal Missing, Incomplete or Failing Integrity CheckI-011 photoAlso: Critical control pointSealer power too low or too high · Cap torque incorrect (loose cap will not seal) · Wrong or missing foil liner Weak or Partial SealI-021 photoPower too low · Conveyor too fast · Head too high Foil Burnt, Scorched or Cap DeformedI-031 photoPower too high · Conveyor too slow or stopped under the head · Head too low Foil WrinkledI-04Uneven cap torque · Bottle neck finish damaged or uneven · Too much heat Foil Stays in the Cap (Does Not Bond to Bottle)I-05Insufficient heat · Wrong liner type for the bottle material · Bottle rim contaminated with product dust Water Tank Alarm / Low Water LevelI-06Also: Cooling water refillCooling water level low (evaporation or use) · Poor circulation or blocked cooling line · Cooling pump failure Bottles Without Foil Not Rejected (or Good Bottles Rejected)I-072 photosAlso: Foil (liner) detection sensorFoil sensor height not set for the bottle and cap (too far from the cap) · Sensor sensitivity drifted · Sensor not centred over the cap Bottle Stuck Under the Sealing HeadI-081 photoAlso: Burning riskBottle tipped or wedged under the blue sealing head · Head set too low for the bottle · Guide rails too tight at the sealer

M

Metal Detection & Checkweighing

Metal Detector Fails Challenge TestM-01Also: Critical control pointSensitivity drift · Wrong product setting · Test piece passed off-centre or at the wrong speed Metal Detector False RejectsM-02Product effect not learned for this product · Sensitivity set too high · Vibration or electrical interference Reject Mechanism Not WorkingM-03Low air pressure · Reject timing wrong · Reject sensor failure Checkweigher Rejecting Good Bottles or DriftingM-04Not zeroed or calibrated · Vibration or drafts · Conveyor speed changed

E

Electrical, Utilities & GMP Events

Inverter Failure (All Machines)E-01Power interruption or phase loss · Motor overload or mechanical jam · Over-current, over-voltage or under-voltage Machine Will Not StartE-02Emergency stop pressed · Guard or door open · Air pressure low Sensor Not DetectingE-03Dirty lens · Misalignment · Loose cable Wrong Component Found on the LineE-04Incomplete line clearance · Wrong material issued · Previous batch materials left on the line Reconciliation DiscrepancyE-05Counting or recording error · Unrecorded rejects or samples · Materials lost or mixed

Guides & procedures

Introduction

Responsibilities1.4

Safety, Hygiene & PPE

Safety, Hygiene & PPE: overview Required PPE2.1 Before entering2.2 Safe working rules2.3

Line Overview

Line sequence3.1 Critical controls3.2

Reference Machine Settings

Reference settings for a 30-count bottle. Settings change with product, bottle and cap; always use the validated settings for the product in the BPR and record any change.

Bottle unscrambler4.1 Electronic counter4.2 Bottle conveyor4.3

Line Operation Procedure

Line clearance5.1 Pre-start inspection5.2 Printer set-up5.3

Machine Operation & Checks

Capsule polisher6.1Removes powder and dust from filled capsules and improves appearance before bottling.Inkjet printer6.24 photos Bottle unscrambler and feeding conveyors6.31 photo

Quick Fault Finder

Quick Fault Finder7

Cleaning & Status Labels

Line cleaning8.1 Green CLEAN status sticker8.2 Equipment and material status8.3

Packaging GMP & Documentation

Packaging controls9.1 Risks assessed9.2 Reconciliation9.3

Typical Cap Application Torque

Typical Cap Application TorqueAppendix A

Glossary

GlossaryAppendix B

Line Clearance Checklist

Line Clearance ChecklistAppendix C

Start-Up Sensor & Safety Test Checklist

Start-Up Sensor & Safety Test ChecklistAppendix D

Capper — Reference Machine Settings4.4

Induction sealer — Reference Machine Settings4.5

Conveyor speeds along the line4.6

Bottle feeding

5.4

Desiccant insertion5.5

Product lifter and counter (main filling machine)5.6

Induction sealing5.8

In-process checks5.10

Batch completion and final line clearance5.12

Ribbon coder and printing station6.4

Desiccant inserter6.53 photos

Product loading hopper, elevator and counter6.62 photos

Capper — Machine Operation & Checks6.76 photos

Foil detection sensor6.82 photos

Cap height (cap fit) sensor6.9

Induction sealer — Machine Operation & Checks6.101 photo

Induction seal check6.11

Cap torque check6.12

Metal detector challenge test6.13

Key records

9.4

Metal detection principles9.5

Checkweigher9.6

Batch and lot9.7