Bissell Homecare Home Care has installed a brand new packaging line for its carpet cleaning products (using HDPE HDPE bottles ranging from 8 to 60 ounces). The production line is located in the newly built innovation center in Bissell with maximum operating speed. Up to 120 bottles/minute.

Since 1876 Bissell has been producing and selling high-quality floor care products such as deep cleaners, vacuum cleaners and detergents. In addition, the company has established a leading position in the global industry through unremitting efforts for more than one hundred years. The company's most famous product is a carpet mechanical sweeper, which appeared 50 years earlier than vacuum technology.
In 2008, Bissell invested more than 9 million U.S. dollars in the refurbishment and upgrading of existing plants at MI Walker Falls. The event was finally presented to everyone today is the Bissell innovation center. At that time, Bissell's refurbished area reached more than 35,000 square feet, and the expansion area reached nearly 5,000 square feet. In addition, Bissel also specifically built a 5,000-square-foot open-air platform.
This base renovation project completely consumed the company's two-year time. In August 2009, the Innovation Center completed the completion acceptance and was officially put into use in October of that year.
Net weight anti-fall waterfall filling
Bissel has independently designed a HDPE HDPE bottle that is stored in a large box. During the interview, the factory's newly upgraded packaging line is packaging 60-ounce bottles. Initially, workers manually placed rectangular empty bottles on the packaging line. Subsequently, the Videojet Excel ink jet printer by Videojet Technologies was responsible for printing product lot numbers and production dates on the bottom of the empty bottles before the bottles were sent to Serac's 16-head net weight anti-falling gravity filling machine. Then, the feeding screw conveyor at the bottom of the filling machine conveys the empty bottles to the rotating starwheel and finally to the 16 platforms of the filling machine. Because the bottleneck is off-center, the star wheel needs to have a high positioning accuracy to ensure that the filling nozzle is just above the bottle mouth.
In order to improve filling accuracy, the company is equipped with load cells for each individual platform. When the empty bottle enters the filling machine, the weighing sensor first measures the weight of the empty bottle, and then the industrial computer controller opens the filling valve. When the weight of the product measured by the sensor reaches a set value, the valve is immediately closed. In addition to calculating the net weight of the bottling bottle, the control system on the filling machine is also responsible for recording the processing and filling data for each bottle and providing immediate production feedback.
For example, the control system can count the weighted average and standard deviation of filling weights in any production cycle when monitoring the running time of the packaging line. In addition, the system can also detect tare weights and list the volume of products that are underfilled or transitioned, thereby telling the operator how much of the product's weight meets established standards. When an empty bottle is filled, the operator simply sets the options from the computer menu and the computer automatically sets the filling parameters and begins filling.
The advantages of the new bottle
The company upgraded its packaging line for a new product, Carpet Concentrate Cleaner, to meet the different packaging needs of 7 sizes (8-60 ounces). The new product is twice as concentrated as the previous product. Bissel partnered with the creative agency Product Ventures to recreate a beautiful new packaging based on the original design.
The entire package design covers the bottle, caps and labels. Product Ventures has designed a special structure for the 2x concentrated formula cleaner and added ergonomics and the concept of proper distribution to increase the added value of the product, thereby bringing new experiences to consumers. The new bottle is almost half smaller than the original one, which is mainly because the proportion of the new formula has been greatly improved compared with the past. However, the performance of the new product has not been compromised due to the reduction in size, and its cleaning capacity is still very strong. In addition, reducing the package size will also help the company promote environmental protection and reduce the negative impact of plastic on the environment.
This new bottle also takes up less shelf space than before and can be easily carried, stored and used by consumers. The new packaging is equipped with a built-in measuring cap to provide consumers with a simpler and more environmentally-friendly carpet cleaning and deep interior decontamination solution.
Like all Bissell's other deep cleaning formulations, the 2x enrichment product has been successfully certified by the EPA Green Design (DfE), which means that the new product has excellent environmental safety features. After joining the DfE project, Bissel has been committed to developing products that are beneficial to human health. In addition, they are constantly improving product formulations to minimize the environmental impact of the product itself.
Rotary sealer
After leaving the filling machine, the bottles were transported by starwheels to the five-head rotary sealer provided by Fowler Products. The bottles are fed into a continuously operating capper through a feed screw conveyor and then through a star wheel to the rotating label plate in the upper part of the central platform. Finally, the worker added a bottle cap to the floor funnel and eventually rose to the top funnel through a non-slip elevator.
The rotary sorting machine adopts an open decentralization configuration, and the cap falls into the sealing machine after being dropped into the sorting machine, and then enters the sealing machine. Because these conical caps have a height greater than the diameter, Bissell specifically used a Fowler universal series sorter, through which the caps can drop directly into the grooves of the rotating disc.
When the rotating disk passes through a selected area, the cap opening upward in the groove is immediately thrown into the bowl. Subsequently, the cap enters the sealing chute and finally falls into the capper.
After this, the rotary cap transfer star will pick up the cap. When the device is rotated, the bottle cap is sent to the cover clip inside the capping head, and the cap grip is rotated and lowered immediately after the cap cap is gripped until the cap is completely fastened to the bottle cap. Bissell's cap has a smooth, tapered side that slides easily out of the cap holder. Therefore, the clip used by Bissel is a vacuum suction cup. The suction cup has better fixing ability than ordinary mechanical grippers.
When the cap is fixed, the vacuum is released immediately. Once the set torque is reached, the clamp automatically releases the cap and returns to its original position. If the sealing machine detects that the bottle slot is empty, that is to say without any beverage bottle, the device automatically stands by and does not release the bottle cap there.
Conical caps of the same size are suitable for all sizes of bottles (no spray caps are required). This bottle cap is produced by Gem Plastics.
Shrink sleeve label on bottle cap
The tested bottles were then sent to a Model 35 pw ps polystyrene labeler from Accraply (a subsidiary of Barry-Wehmiller Companies Inc.). The device is responsible for labeling the front and back of the bottle. The labeling machine uses frequency-conversion speed conveyor belts to accommodate bottles of different sizes. The device is also equipped with servo-driven labeling heads, all of which can be directly controlled via the HMI touch screen. In addition, the air-assisted contour tracking label peeling system also polishes the label to make it more fit on rectangular bottles. Operating parameters are stored in the computer's memory for touch extraction.
Afterwards, these bottles enter the Axon shrink sleeve labeler. The device can apply shrink sleeve labels to the bottle caps. When labeling, the film is pulled out by the roller, then pulled through an electric film retracting system to the top of the machine and finally into the application chamber.
The film entering the chamber is pulled through a series of rollers and then pulled to the bullet head, which then pulls open the tubular film. In this process, two step drive rollers must be connected to the print register system to ensure that the length of the film is within the specified range.
The printing register system located on top of the film mandrel is equipped with Tri-Tronics Smarteye photoelectric sensor, which enables vertical and horizontal automatic adjustment. When the sensor detects the container, the vacuum in the suction cup is instantly released, and then the film is pushed by the piston to the top of the container. Once the labeling area is confirmed, the new label is finally attached to the product package through a set of pulling rollers.
Only one set of suction cups is responsible for fixing the label, and then the excess part of the label is cut off by the side cutting blade. When the film is removed, the jaws return to their original position and are ready to pull the film for the next container.
After passing through the Axon steam tunnel, the bottles will shrink immediately and tightly adhere to the bottle cap. The bottom film also fits exactly on the bottom of the bottle cap. The accuracy is very high.
The set of marked bottles is then transported to a Label-Aire pressure-sensitive local labeler. The device is responsible for labelling the local area of ​​the bottle and is only suitable for specific situations. During the interview with the reporter, this equipment did not operate.
Bottle cap is tightened
The unloaded bottle is then passed through a star wheel and sent to the inline sealer provided by Kaps-All Packaging Systems. The running time of this packaging line is very flexible. It is mainly responsible for sealing the flat lid. The sealed bottle was then fed into an induction sealer from Pillar Technologies.
The bottles were first passed through an inline ACT-8 automatic eight-spindle sealer (provided by Accutek Packaging Equipment Co., Inc.). After the induction sealer measured the tightness of the caps, the device began to reverse the cap until tightness. Reach the established value. Eight tightening spindles are self-adjusting to ensure torque accuracy is maximized and disk wear and scratches are effectively reduced. In addition, adjusting these spindles allows the machine to adapt to a variety of sizes, shapes, and models of containers.
Finally, the bottles were checked by Teledyne Taptone's inspection system to detect leaks. When the container enters the device, both ends of the conveyor belt will be automatically tightened, thus fixing the space on the top of the container and eventually causing the device to pause. Afterwards, the sensors in the inspection system start to detect the dimensions of the container. If it exceeds the acceptable range, the bottle will be automatically rejected.
Servo drive packing machine
The bottles were then sent to the Hamrick Manufacturing & Service cartoner. Once the bottle enters the equipment, it is divided into multiple channels by the servo-controlled partition system. This helps to achieve the same accumulation of single channels and prevent clogging. The reporter found that Bissell divided the 60-ounce bottle into three lanes. The company stated that although the boxer can separate up to six lanes, the 60-ounce bottle is more than enough to divide into three channels.
The case packer with the letter D in the model is a state-of-the-art product from Hamrick. The machine is equipped with a built-in servo control separation system. The software program controller inside the device is responsible for controlling the overall operating state of the machine, while the partitioning and packing system is controlled by the PLC programmable controller, which is equipped with a pre-programmed selector switch and a programming pad.
In addition, a high-speed surge control conveyor was installed on this equipment to allow the computer to automatically adjust the channel speed to meet the need for faster and slower channel speeds.
The person in charge told the reporter that the product conversion speed mainly depends on the 20 independent time values ​​in the PLC and the running speed of the 255 channels in the servo control separation system. The operating parameters of each container are stored in the computer's memory, and the operator can extract information through the man-machine interface.
The machinery of Southern Packaging Machinery was responsible for erecting the corrugated boxes. The cartons then entered the Hamrick packing machine, and the direction of entry was consistent with the direction of bottle transport. The cartoner can load two corrugated boxes at a time. When the machine releases two cartons at the same time, the flight bar activates and pushes the carton to the loading area.
At this point, the machine will release a certain amount of bottles at the same time, into two cartons. These bottles also need to enter the filling area and a valve controls their specific orientation. When both cartons and beverage bottles are placed in place, the plate below the bottle opens instantly and the bottle falls down into the carton. The carton is quickly lifted when the bottle is released, and then slowly lowered to increase the bottle. The buffering force when falling, reduces the possibility of the glass bottle being crushed.
The cartons that hold the bottles will then pass through the Top Paste Machine produced by Highlight Industries. The device is equipped with adjustable side belts that allow for automatic folding of the lids. The precision and consistency of the glue application are also very high. After the glue is applied, the inkjet printer is responsible for printing the production date and lot number of the product on the cardboard box. This inkjet printer includes a Foxjet ProSeries print head and an Inkjet AnserTM smart print system.
Afterwards, all the boxes were stacked together by the ground level palletizer provided by Lambert Material Handling. The pallets were then covered by the Highlight Industries Freedom 6500 rotary wrapper. The film covered every corner of the pallet and its stability was effectively maintained. Promote.
Bissell standardized and installed integrated control over the entire packaging line to ensure the smooth operation of the production line. The conveyor belt and the product stacking channel are closely connected. In the event of product clogging, the conveyor belt will automatically adjust the operating speed to relieve the clogging pressure. In addition, the online machines can also “communicate” with each other. The sensors can adjust the speed of the corresponding devices by sensing the status of the products at each stage.

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