IE990187A1 - A bottle processing method and system - Google Patents

Abstract

Returned glass bottles are processed in a plant (4). Each pallet is labelled with a batch code, a sub-batch code, and a pallet number. The plant (4) has three carousels having an endless loop conveyor with infeed and outfeed sections (25,26). An outfeed section stand (29) holds washed crates (32) received from a washing system outfeed conveyor (35). Used crates are placed in a washing station infeed as they are emptied, and washed crates are delivered to a sorting outfeed station. Empty pallets are inspected in a quality control area before return to the plant outfeed section. <Figure 1>

Description

“A bottle processing method and system” W* Introduction The invention relates to processing of bottles, and particularly bottles which have been used by public houses and hotels and are to be re-used in a bottling plant. Such bottles may, for example, be beer bottles which are collected by wholesalers when making deliveries.

One of the major problems which arises in such an operation is the fact that there is often very little care taken by the retailers in the manner in which they return bottles and a wide variety of non-returnable or third party bottles may be returned in crates to a particular wholesaler.

Another problem which arises is ensuring that bottles which are processed will be delivered to the bottling plant in batches of the correct type and with little or no damage. Any mistakes made in the supply of bottles to a bottling plant can lead to a large amount of down time and is extremely inconvenient. It is therefore very important that steps are taken to ensure the best quality supply of bottles to the bottling plant.

The present invention is directed towards providing a method and system to achieve these objectives.

Statements of Invention According to the invention, there is provided a bottle processing method comprising the steps of: receiving a consignment of bottles in crates which are in turn on pallets, and , ,,,. 30,.., ____checking4ha.consignment; and storing it in a marked storage area, j OPEN TO PUBLIC INSPECTION UNDFP INT πΓ6 I&I r?ON 28 AND PULE 23 IE 9901-87 -2transferring the infeed bottles to a sorting infeed section, placing the bottles on the conveyor, checking quality of crates as they are emptied and separating out damaged crates, at a sorting outfeed section, sorting the bottles by selectively removing them from the conveyor and placing in selected crates, and placing the sorted bottle crates on pallets.

In one embodiment, the step of checking a received consignment comprises the sub-steps of checking origin of the pallets and quantities of crates.

Preferably, each pallet of a received consignment is individually labelled.

In one embodiment, each label indicates a batch code and a pallet code.

In a further embodiment, there is a batch code for a full consignment and a sub-batch code for the type of bottle within the consignment.

Preferably, a record is kept of each pallet as it is transferred to the infeed conveyor section.

In another embodiment, used crates are placed in a washing station infeed as they are emptied.

In a further embodiment, washed crates are delivered to the sorting outfeed section for filling during sorting.

IE 9901S7 -3In one embodiment, the sorting conveyor is arranged in an endless loop as a carousel, the infeed section being on one side and the outfeed section the opposite side.

Preferably, the pallet labels are retained at the infeed section as the pallets emptied.

In a further embodiment, sets of empty pallets are removed from the infeed section to a quality control area and inspected before return to the outfeed section.

In a further embodiment, the quality control area comprises segregated areas for holding sets of pallets for inspection.

In a further embodiment, pallets filled with crates of sorted bottles are labelled to indicate the bottle type, date of processing, and the batch code.

Preferably, the infeed section is cleared at the end of a batch and a record is made of quantities on part pallets at the outfeed section.

In another embodiment, the partial pallets are completed by the following batch so that only full pallets of processed bottles are delivered.

According to another aspect, the invention provides a bottle processing system comprising means for performing a method as described above.

Detailed Description of the Invention The invention will be more clearly understood from the following description of some embodiments thereof, given by way of example only with reference to the accompanying drawings in which:IE 990187 -4Fig. 1 is a diagrammatic plan view of a bottle processing system and a flow diagram illustrating the processing methods; Fig. 2 is a plan view of a carousel of the system; Fig. 3 is a perspective view showing a completed pallet; and Figs. 4 to 8 are representations of control records maintained for the message.

Referring to the drawings, and initially to Fig. 1 there is shown a bottle processing method in flow diagram format, and also a plan view of a system for implementing the method. Bays 1 are used for storage of received consignments of bottles which are stored in crates, which are in turn stored on pallets. The flow into the bays 1 is indicated by the arrows 2. The received bottles are processed one batch at a time by initially being transferred as indicated by the arrows 3 to the processing plant 4. Pallets are temporary freed up during operation of the plant 4 and they are transferred to an inspection area 5 as indicated by the arrows 6. After inspection, these are transferred as indicated by the arrow 7 back into the plant 4 for use in storage of processed bottles. Filled crates of processed bottles are supplied as indicated by the arrows 8 to final dispatch storage areas 9. These pallets have been processed to ensure that they are of the correct origin and are of the correct quality. Also, the crates have been checked to ensure that they satisfy stringent quality requirements, and the crates have also been washed. The bottles are sorted according to category so that they can be immediately used in a bottling plant without additional quality control.

In more detail, consignments of bottles arrive on transport lorries and a supervisor checks the consignment against a driver docket and notes any discrepancies. The driver signs off on any discrepancies. A check is also made at this stage for “rogue” pallets i.e. those from a foreign source.

IE 9901S7 -5The input pallets are transferred to the storage bays 1 in batches which are delineated by the bay markings. Each pallet is labelled with a batch code, a sub-batch code, and a pallet number. For example, the total code may be 9623 A 7. In this example, “9623” is the batch code, “A” is the sub-batch (which indicates the particular type of bottle such as 1 pint or 330 mis), and “7” indicates that it is the seventh pallet in this batch.

When the processing plant 7 is ready, pallets are transferred one at a time to a particular carousel within the plant 4. The plant 4 comprises three carousels, each of which operates independently on one batch at a time. A single such carousel is shown in Fig. 2 and it comprises infeed bays 20 for receiving full pallets from the storage bays 1. In Fig. 2, there is shown a full pallet 21, a pallet 22 which has been emptied and is ready to be taken away for inspection at the inspection area 5, and a pallet 23 with damaged crates placed on it for removal from the process. The carousel comprises an endless loop conveyor having an infeed section 25 and an outfeed section 26. The infeed section 25 comprises a mesh platform 28 upon which full crates are supported as bottles are transferred on to the infeed conveyor section 27. When empty, the crates 32 are carefully inspected and if the quality is adequate they are placed on a conveyor 30 which is an infeed conveyor for a washing system 31.

At the outfeed section 26, there is a stand 29 for holding washed crates 32 which have been received from a washing system outfeed conveyor 35. Outfeed bays store inspected pallets for filling with sorted bottles placed in washed crates. Two such pallets 36 are shown in Fig. 2. An empty pallet 37 is ready for use.

In more detail, as the pallets are transferred into the infeed section bays 20, the forklift driver keeps a record on a document 50 shown in Fig 4. This record includes the carousel number, the batch number, the date, and confirmation of each pallet in sequence the grid illustrated. It thus provides a comprehensive record of transfer of the input pallets to the processing plant carousel. The personnel at the carousel then transfer the crates to the platform 28 and transfer the bottles to the conveyor infeed section 27. An important -6aspect of the method is that the crates are thoroughly checked at this stage and only good crates are placed on the washing system infeed 30. The individual label on each pallet is retained as the pallet is emptied and a record 60 is completed for transfer of sets of ten empty pallets to the inspection area 5. The washing system 31 comprehensively washes the crates 32 which are fed into it and returns them via the outfeed conveyor 35. The operators selectively pick the bottles from the conveyor outfeed section 26 so that they are sorted as they are placed into relevant crates and in turn placed onto relevant pallets 36 in the bays at the outfeed section of the carousel.

A full pallet of sorted bottles is labelled to indicate the bottle type by use of a colour code, the date of sorting, and the batch code. A sample 70 is illustrated in Fig. 6. A supervisor updates a batch control sheet 80 shown in Fig. 7, and when a pallet is removed to a dispatch area 9 the supervisor updates the record 70 shown in Fig. 6. At this stage, the full pallets are ready for dispatch.

When a batch is completed, the infeed side of the carousel is cleared and a record is made of the extent of any partial pallets at the outfeed side. These are retained at the carousel and are completed at the next batch so that only full pallets are transferred to the dispatch area 9.

Regarding the inspection area 5, all pallets are carefully checked to ensure integrity. This is very important as it helps to ensure safe transport of the processed bottles to the bottling plant. A record 81 is made of the inspection, this record being shown in Fig. 8. This check also provides a physical reconciliation for financial and inventory control purposes. A comprehensive database system is fed with the records illustrated and so there is comprehensive tracking of all inventory beginning with the consignment note details, trailer number, time and the time the batch is started. Daily summaries and combined summaries are generated from these records according to quantity, time and bottle type criteria. For example, a turn out worksheet indicates the batch number, the carousel, the start date, the end date, and for each type of bottle it indicates:IE 990137 -7the number of pallets, the number of bottles, the number of full crates on a partial pallet, the number of loose bottles, and the number of damaged crates, and the full batch bottle turn out.

The system thus allows planning of throughput on a weekly basis. There is turnout reporting by customer and by batch for pallets, crates, and bottles. Full traceability is achieved. Also, the system achieves full stock control of unsorted, non-conforming, and sorted bottles, crates and pallets. This means that all stock transfers (both external and internal) are recorded and running balance and history of all transactions is available.

It will also be appreciated that excellent quality is achieved because of the in-line inspection methodology and arrangement of the processing system. Rogue and damaged bottles, crates, and pallets are all filtered out at a very early stage and are handled with minimum handling time and processing disruption.

The invention is not limited to the embodiments described but may be varied in construction and detail. For example, the method and system may be used with other containers such as jars.

Claims (15)

Claims

1. A bottle processing method comprising the steps of: receiving a consignment of bottles in crates which are in tum on pallets, and checking the consignment and storing it in a marked storage area, transferring the infeed bottles to a sorting infeed section, placing the bottles on the conveyor, checking quality of crates as they are emptied and separating out damaged crates, at a sorting outfeed section, sorting the bottles by selectively removing them from the conveyor and placing in selected crates, and placing the sorted bottle crates on pallets.

2. A method as claimed in claim 1, wherein the step of checking a received consignment comprises the sub-steps of checking origin of the pallets and quantities of crates.

3. A method as claimed in claims 1 or 2, wherein each pallet of a received consignment is individually labelled.

4. A method as claimed in claim 3, wherein each label indicates a batch code and a pallet code.

5. A method as claimed in claim 4, wherein there is a batch code for a full consignment and a sub-batch code for the type of bottle within the consignment. -96. A method as claimed in any preceding claim, wherein a record is kept of each pallet as it is transferred to the infeed conveyor section.

6. 7. A method as claimed in any preceding claim, wherein used crates are placed in a 5 washing station infeed as they are emptied.

7. 8. A method as claimed in claim 7, wherein washed crates are delivered to the sorting outfeed section for filling during sorting.

8. 10 9. A method as claimed in any preceding claim, wherein the sorting conveyor is arranged in an endless loop as a carousel, the infeed section being on one side and the outfeed section the opposite side. 10. A method as claimed in any of claims 3 to 9. Wherein the pallet labels are 15 retained at the infeed section as the pallets emptied.

9. 11. A method as claimed in any preceding claim, wherein sets of empty pallets are removed from the infeed section to a quality control area and inspected before return to the outfeed section.

10. 12. A method as claimed in claim 11, wherein the quality control area comprises segregated areas for holding sets of pallets for inspection.

11. 13. A method as claimed in any preceding claim, wherein pallets fileed with crates of 25 sorted bottles are labelled to indicate the bottle type, date of processing, and the batch code.

12. 14. A method as claimed in any preceding claim, wherein the infeed section is cleared at the end of a batch and a record is made of quantities on part pallets at the 30 outfeed section. - ίο

13. 15. A method as claimed in claim 14, wherein the partial pallets are completed by the following batch so that only full pallets of processed bottles are delivered.

14. 16. A method substantially described with reference to the drawings.

15. 17. A bottle processing system comprising means for performing a method as claimed in any preceding claim.