We have been successfully involved in Industry 4.0 projects for several years now. Below we present some selected case studies.

Closed Loop application between CapWatcher III and Netstal injection molding machine

For the first time, together with the Swiss injection molding machine manufacturer Netstal, we presented a CapWatcher as part of a complete control circuit, also known as closed loop, at the Drinktec 2017 trade show. The object of the simulation was a water closure produced live on site.

An external influence was simulated on the injection molding machine to create a diameter change in the closure. The CapWatcher measured this deviation from the standard. Subsequently, via an OPC-UA interface, it informed the injection molding machine that the cap diameter was moving towards its limit value, and that intervention was necessary.

From that moment on, the injection molding machine automatically counteracted the trend by making appropriate adjustments to the associated process parameters (for example, injection pressure, melting temperature). After a very short time, the machine continued to produce closures with a standard diameter.

Thanks to the CapWatcher’s feedback, the machine knew exactly which process parameters it had to change. The fully automatic control loop was closed!


Support in low-manning operations at Australian beverage bottler

As early as 2010, a closed loop solution was implemented at the subsidiary of a global player in Australia. In this case study, three CapWatcher and five Sample-PreWatcher systems are positioned inline behind each injection molding machine. In addition, all lines are equipped with a Diverter for loading Octabins.

Each production line is connected to the customer's Manufacturing Execution System (MES) via an OPC interface. The MES defines a maximum filling quantity per packaging unit. Once this is achieved, the INTRAVIS system provides information to the MES that a fully loaded packaging unit is ready for collection. Driverless transport systems then exchange the full packaging units for empty ones, and take the full units to the warehouse or directly to the shipping department.

For the entire production line, this means that no machine operators are required for the production and loading of the preforms and closures produced.


Automatic readjustment of the dispenser head of a labeler

An ever-increasing label offset is a common problem in labeling. Since August 2018, we’ve integrated a solution at a German global player in which a LabelWatcher is interfaced with a linear labeling system. Based on the average value of the last 40 tested objects – this value can be variably adjusted from line to line – the dispensing head of the labeling system is always optimally aligned. At the same time, rejects can be avoided and the attractiveness of the decoration increased. After the successful test phase in the middle of this year, this functionality will now be rolled out to all lines at this location, followed by all LabelWatchers worldwide in the entire corporate group.

In the future, we will also offer this solution for rotary labeling systems.


Automatic readjustment of the dispensing head of a linear labeler

Automatic readjustment of the dispensing head of a linear labeler


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