EP3310664B1 - System and method for filling containers - Google Patents

Description

The invention relates to a system and a method for filling containers.

Systems and methods for filling containers are already known. Empty containers, such as bottles, are stacked in boxes on pallets and depalletized by a depalletizer. The boxes are then transported to an unpacker, which unpacks the bottles. The unpacked bottles are then fed to several treatment stations, for example a bottle washing machine, a filler and a labeling machine, before they are sent back to a packer. The boxes are washed in a box washer and also fed back to the packer. The freshly packed boxes are then fed to a palletizer again and finally leave the system. Such systems are, for example, in EP 2 256 041 A1 , DE 32 35 223 A1 , WO 2010/018224 A1 , DE1291145 , GB 1,105,809 and U.S. 4,720,797 described.

The production time for the containers and for the crates differs significantly, however, since compared to the number of crates there are a large number of bottles which, moreover, have to be passed through more stations than the crates. In particular, a cleaning machine for containers (Reima) or a pasteurizer can accommodate several thousand containers. Thus, when changing products, the problem arises that when second containers are fed into the system in second boxes and are unpacked, first containers and first boxes are still in the system. It is possible that there is an excess of first containers in the system for which the first empty crates have to be added. At the beginning of the production of the second containers, when they are introduced into the container flow, there is an excess of second boxes, which must be removed from the system in order to avoid a blockage in the production process. Another possibility is that the system has to be completely emptied when changing products. This means that so far the changeover from one product to another has been carried out empirically by observing the system with regard to the filling of the system with boxes and containers. However, the estimated number of crates to be added or removed usually only corresponds imprecisely to the actual situation. Time is lost due to incorrect assessments and decisions by the operating personnel. In addition, the necessary changes must have been made at individual treatment stations so that the subsequent container or box can be treated. This requires the people involved to coordinate with one another. The duration of the change is unnecessarily long and often fluctuates very strongly
Proceeding from this, the present invention is based on the object of providing a system and a method for filling containers that allow simple and quick changeover from a first container in a first box to a second container in a second box.

According to the invention, this object is achieved by the features of claims 1 and 11.

According to the present invention, a system for filling containers comprises an empties task, via which boxes with empty containers are fed to the system in order to refill them, an unpacker that removes the containers from the boxes, at least one treatment station, in particular for cleaning and Filling the containers, at least one treatment station, in particular a crate washer for the crates, a packer to which the finished containers and the empty crates can be fed, for packing the containers into the crates. A box distribution switch that can feed the boxes to the packer or discharge the boxes from the system, i.e. can bypass the packer. The system further comprises a first counting device for determining the number of containers supplied to the system and a second counting device for determining a number of boxes which are passed to the packer. The system also has a calculating device which, on the basis of signals from the first and second counting devices, can calculate how many crates still have to be supplied for the determined number of supplied containers so that all of the containers can be packed.

Because it can be determined exactly how many containers have been fed into the system and how many boxes have already been fed for the packer, it is known for how many containers a box has already been fed and for how many containers no box has yet been fed. ie how many more boxes are still necessary. The system lacks this number of crates, since at the start of production, excess crates were diverted via the crate distribution switch, for which no corresponding containers had yet been available in order to prevent the system from jamming. In addition, crates that were found to be defective by a crate inspection device and were rejected were removed if necessary. It is also possible for crates to be ejected for the purpose of sorting, sorted manually or automatically, and then reintroduced. In such sorting stations, for example, third-party containers can be removed and replaced with correct containers, missing containers can be inserted, etc. The boxes that are discharged or re-introduced can also be counted.

In this way, the exact number of boxes that need to be replenished at the end of production can be determined. This results in a shorter and more reproducible one Changeover, higher availability of the system and greater effectiveness, which in turn results in lower costs for the operator.

The second counting device can have at least one counter for determining the number of crates supplied, the at least one counter preferably being arranged in the area of the empty container and / or in the area of the depalletizer and / or in the area of the unpacker. It is advantageous if a first counter is arranged at the very beginning of the system, since it is then always known how many boxes are already in the system at a certain point in time. Additionally or alternatively, a counter can also be provided in an area of the box distribution switch up to the area of the packer. In this way it can be determined directly how many crates are fed to the packer. If a counter is provided in front of the distribution switch and after the distribution switch on the transport route to the packer, the number of crates removed can be determined by subtracting the number determined after the distribution switch from the number determined in front of the distribution switch. The corresponding counter can also be integrated in the distribution switch or in the packer.

The expression “in the area” means here that the corresponding counters can be integrated into the corresponding modules and / or are then arranged on the transport route before the subsequent module.

The first counting device can comprise at least one counter for counting the containers supplied, the at least one counter preferably being arranged after the unpacker, viewed in the direction of transport. It is advantageous to count the containers after the unpacker, as it can happen that not all spaces in the boxes are filled with containers. The number of containers supplied can thus be recorded more precisely. Viewed in the direction of transport, the accuracy of the counting improves with increasing distance from the empty container, since then, for example, broken or ejected containers are automatically recorded during the count. However, it would also be possible to determine a corresponding number of containers when empties are fed in or at the depalletizer, for example by counting the number of pallets (if the number of boxes per pallet and container per box is known). However, a corresponding count is less precise than that described above.

It is possible for the first counting device to have at least one second counter which can determine a number of removed containers. For example, if there is a bottle inspection device in front of the filler that sorts out defective containers, a corresponding number can be counted and deducted from the number of recorded supplied containers.

In order to enable an even more precise determination of the supplied containers, for example the number of supplied containers recorded by the at least one counter can be corrected by the calculation device by a correction value, in particular empirically determined. If, for example, the containers are counted relatively at the beginning of the entire transport route, for example in the area of the unpacker or the cleaning machine, and it is known from previous processes how large the proportion of rejects is up to the packer, the counted number can be corrected accordingly become.

It is possible that the calculation device can send signals to a display, in particular to a mobile reporting system, which visually or acoustically indicates how many empty boxes and / or in particular pallets are still to be added to the system, for example via an empty frame task. The operating personnel then know exactly how many empty boxes or how many pallets with empty boxes still have to be fed in via the empty frame feed and can arrange for the corresponding. The display can also be a stationary display on the pallet feeder from the depalletizer, so that the forklift driver knows which and how many pallets of which type he has to place where.

However, it is also possible that the calculation device sends corresponding signals to a control unit that controls a transport device that automatically transfers the empty boxes, in particular the corresponding pallets that were previously ejected from the system to avoid an excess or for other reasons System supplies again. This makes the handling of the system much easier.

In order to buffer the boxes, buffer sections can be provided for the boxes on the transport path. Corresponding box stores or box magazines can also be provided, for example. Corresponding buffers allow greater leeway in process management and in particular prevent individual transport sections from being blocked and also enable continuous process management. For example, there can be buffer sections between the empty container and a palletizer and / or between the depalletizer and the unpacker and / or between the crate washer and the box distributor and / or between the box distributor and the packer and / or between the depalletizer and the distributor and / or an empty frame task and a depalletizer and / or between the packer and the palletizer. The system is advantageously designed in such a way that a depalletizer is provided between the empty container and the unpacker and a palletizer is arranged after the packer. The empty crates ejected by the crate distribution switch can then be fed to the palletizer via a corresponding transport route. This means that the palletizer, which is provided for the completely filled containers in the boxes, can also be used for the discharged empty boxes, which are then available on pallets in order to be accepted again from an empty frame task to boxes at the end of the process to feed on.

Advantageously, there are several separating devices, in particular box stoppers, on a transport route from a depalletizer to a palletizer. The separating device can also be a box conveyor, which is stopped to separate the box streams. In this way, successive boxes, in particular boxes of different types, can be prevented from being driven open. This means that areas between different treatment stations can be kept free. This also enables different products to be subsequently treated in one system.

It is possible that at least one separating device is also provided for the containers on their transport path and the system preferably also includes a new glass feed, with the new glass container flow advantageously also being able to be accumulated by a separating device. New glass can thus be supplied in a targeted manner. The separating device can also be a container conveyor which is stopped to separate the container flows.

The function signals from different treatment stations are advantageously used to count the containers or boxes. The same can be implemented simply and inexpensively. For example, the depalletizer can be connected to the second counting device, with signals being generated during depalletizing, on the basis of which the second counting device counts the boxes. This means, for example, that every time the depalletizer clears a pallet, a corresponding signal is passed on to the counting device, from which, for example, the number of boxes can be determined or the number of containers if the number of boxes per pallet and number of containers per box is known .

In the method according to the invention, the production of a first container in a first box is switched to the production of a second container in a second box. First the first containers are filled into the first boxes and after the last first box has been fed into the system, production of the second can begin immediately afterwards Containers are started in the second boxes, which are then also fed to the system and unpacked. The second containers and the second boxes are then further treated separately in at least one treatment station each. The finished treated second containers are then packed into the finished treated empty second boxes by a packer.

When production of the second container begins, the second boxes are first ejected via the box distribution switch. At the beginning of production means here in a period in which no filled containers are available for packing or more boxes are being conveyed than are needed for packing and there is space on a backlog in front of the packer first treatment stations are located after the unpacker, for example after the unpacker in the area of the cleaning machine and the filler and have not yet passed through the last treatment station (e.g. labeler). The crates must be ejected especially when the first crates are still in an area between the crate distribution switch and the packer.

The second boxes can then be fed to the packer via the box distribution switch so that the finished second containers can be packed there. The distribution switch can be switched over at the earliest when the last first crate is transported over the distribution switch towards the packer at the end of production of the first containers.

At the end of the production of the second containers in the second boxes, the number of second containers that were fed into the system during production is determined. In addition, the number of second boxes supplied to the packer is also determined. This is used to calculate how many empty second boxes are still necessary for the determined number of second containers that have been added. A corresponding number can then be added.

At the end of production means after the last filled crate of a corresponding type has been fed into the system, preferably after the last crate has been unpacked.

The number of crates fed to the packer can be determined in different ways. For example, the number of crates of one type that have been fed into the system can be counted and a number of crates of the same type that have been removed from the system in front of the packer can be subtracted from this, for example via the distribution gate or via an inspection device, etc. The number of crates fed to the packer can also be determined, for example, by counting the number of crates of a type that is passed from the crate distribution switch to the packer, for example through a measuring device, e.g. a light barrier on or after the box distribution switch. The number is preferably determined when the last box has passed the counter.

At the same time, the number of second boxes or the next type that were fed into the system could be counted (for example in the start area of the system when empties are fed in or at the depalletizer). Then, by subtracting the number of containers forwarded to the packer from the number of boxes fed into the system, the number can be determined that was discharged from the system, whereby it is known at any point in time how many boxes are still in the system. If crate sorting is available, the number of crates returned can also be counted and taken into account accordingly.

In principle, it is possible that at the end of production, i.e. after the last container or the last box has been fed into the system, it is calculated how many empty boxes or correspondingly many pallets are still fed to the system for the determined number of containers via an empty frame acceptance must be so that all containers can be packed. A corresponding number of pallets can then be fed to the empty frame reception. This process is particularly precise, as the exact number of pallets required can be fed in, with excess boxes being able to be ejected via the distribution switch. Immediately thereafter, the production of the following product can begin.

It is also possible that at the end of production, second empty boxes on pallets are automatically fed into the system via an empty frame feed and the packer is additionally fed the calculated number of second boxes so that all the containers can be packed.

Then, for example, the number of boxes that were fed into the system via the empty frame feed can also be taken into account in the calculation. The comparison or the calculation can take place relatively late, for example when the filling machine runs empty or even when the last treatment station (usually a labeling machine) runs empty, which enables the number of containers to be determined particularly precisely.

Excess crates fed into the system can, in the case of a very high number, also be ejected via the distribution switch, for example, or they can be removed manually by the operator or simply passed through the packer without being packed. The operator at the palletizer then removes the empty boxes in order to avoid mixed pallets with full and empty boxes.

The number of crates supplied can be determined in the area of the empty container and / or in the area of the depalletizer and / or in the area of the unpacker and / or in the area from the box distribution switch to the area of the packer. According to a special embodiment, the number of crates fed in can also be counted in the area of the empty frame feed in order to obtain an overview of how many empty cases were fed to the system via the empty frame feed. As already explained, the containers are preferably counted in the transport direction after the unpacker.

According to the present invention, the start of the supply of the second containers in the second boxes already starts when there are still first containers and first boxes in the system. This is particularly efficient and enables the changeover time to be significantly reduced.

The crates ejected by the crate distribution switch are fed to the palletizer. In this way, the boxes that are superfluous at the start of production can be stacked on pallets and then fed back to the empty frame feed. In the method according to the invention, separating devices can be actuated which accumulate the second boxes in order to prevent the first and subsequent second boxes from driving open. Separating devices can also be provided which prevent mixing of the first and second containers.

Advantageously, the transport path between the distribution switch and the palletizer is at least as long or a corresponding accumulation path or box storage is provided so that the number of boxes that can be transported on this path is at least the number of boxes (e.g. second boxes) that should have space on a pallet , corresponds. This ensures that a pallet can be fully loaded and transported further by the palletizer without delays.

Advantageously, the feeding of second new glass containers, in particular into the inlet to a cleaning machine, takes place before the second containers are fed from the unpacker to the cleaning machine, in particular the feeding starts when the last first containers are in the cleaning machine and the infeed conveyor of the cleaning machine is / has been stopped. This has the advantage that second containers are available at the packer more quickly.

It can be determined how much scrap is generated and a corresponding number of new glass can be added. The reject can be determined by, for example, the number of containers supplied in an area before the first treatment station the unpacker or at the unpacker is counted and the number of containers after a last treatment station station, for example after labeling by the labeling machine.

According to a particularly preferred embodiment, the containers pass a labeling machine after a filler and the number of second containers supplied after the labeling machine has run empty is counted at or after the labeling machine. A corresponding number of second boxes can then be calculated that is still required to pack all of the containers. Any missing second boxes are fed to the packer. Surplus boxes in the system can be discharged via the distribution switch. In the case of pallet-wise feeding, this has the advantage that exactly as many or at least as many boxes are transported to the packer via the distribution switch as is necessary to pack the specific number.

It is also possible to perform a calculation several times in succession during the production of a certain type of container and crate - how many crates are to be replenished - whereby different counters can be used.

By counting and calculating the ratio of the supplied containers and boxes according to the invention, there is also the possibility that just as much new glass is supplied and correspondingly many boxes are supplied that a pallet with completely filled boxes can be completely loaded.

The second containers or boxes are only treated in the corresponding treatment stations if, if necessary, the corresponding treatment station has been switched to the second container or boxes. A changeover can take place if either an operator initiates a changeover at a certain point in time, or a changeover takes place automatically when the last containers or crates of the first type have passed the corresponding treatment station. By counting the containers and / or crates at several points, a calculation device can also determine when a changeover is necessary. When changing over, a corresponding activation signal can then be generated so that the containers or crates of the second type can then be treated in the treatment station. A corresponding activation signal can also be generated by an operator, for example by pressing a button.

Fig. 1

zeigt grobschematisch eine Ausführungsform einer Anlage zum Abfüllen von Behältern gemäß der vorliegenden Erfindung.

Fig. 2 bis 13

zeigen grobschematisch ein Verfahren zum Umstellen von einem ersten Produkt auf ein zweites Produkt mit einer Anlage gemäß Fig. 1.

Fig. 14

zeigt grobschematisch ein Blockdiagramm für ein Ausführungsbeispiel gemäß der vorliegenden Erfindung.

The invention is explained in more detail below with reference to the following figures.

Fig. 1

shows roughly schematically an embodiment of a plant for filling containers according to the present invention.

Figures 2 to 13

show roughly schematically a method for changing over from a first product to a second product with a system according to FIG Fig. 1 .

Fig. 14

shows a roughly schematic block diagram for an embodiment according to the present invention.

Fig. 1 shows a system for filling containers according to the present invention. The system has an empties task 2, via which boxes with empty containers can be fed to the system in pallets. The pallets can be transported to a depalletizer 10 via the transport path A using appropriate transport means, for example chain conveyors or roller conveyors. The depalletizer 10 is connected to a next station, here for example the crate uncorker and the unpacker 3, via a transport path B. Crate uncorkers and unpackers are combined here, as they are arranged at a short distance from one another and operated or changed over by the same operator. The crate uncorker and unpacker can also be spatially separated from one another. The box uncorker (for crown caps) can also be a box unscrewer (for screw caps). In the unpacker 3, the containers are removed from the boxes and fed to different treatment stations separately from one another. The empty crates are fed to a subsequent treatment station, here for example a crate washer 4, via a transport path C. The empty crates can then either be fed to further treatment stations via a further transport path D and / or are routed directly to a crate distribution switch 5. The box distributor 5 can either convey the empty boxes to a packer 9 on a transport route E, or via a transport route F to a palletizer 11. In the packer 9, the treated and filled containers are fed to the ready-made empty boxes. The crate washer can also be arranged after the distribution switch.

After the unpacker, the empty containers can be fed to the first of several treatment stations via a transport path G. Here, the first treatment station is, for example, a cleaning machine 6, for example a bottle washing machine, which cleans the containers, the containers then being able to be conveyed via the transport path H to a filler 7. For example, a container unscrewing device can also be arranged in front of the cleaning machine. An inspection device 14 can also be provided in front of and / or in the filler, which inspects the containers and, if necessary, discharges them. The filled containers can then be fed to the next treatment station, here for example a labeling machine 8, via a transport path I. In the transport direction after the filler 7, a pasteurizer 21, for example, can also be arranged, which pasteurizes the filled containers. In this In the exemplary embodiment, the pasteurizer 21 is not used. Here the labeling machine is, for example, the last treatment station and the finished containers are transported via the transport path J to the packer 9 and packed. The packer can also have control devices. For example, an empty crate control can be arranged in front of the packer and a full crate control after the packer. These controls are mostly supervised by the operator of the packer.

The filled containers packed in the boxes can then be guided to a palletizer 11 via the transport path M. The fully loaded pallets are then either transported out of the system via the transport path K or can pass through further treatment stations, such as a binder 22 or a pallet labeling machine 23. Finally, the boxes with filled containers can be transported from the system to a sink for full pallets.

However, the empty boxes transported from the distribution switch 5 via the transport path F to the palletizer 11 can also be transported away from the system via a transport path K after the corresponding pallets have been fully loaded, in order to later be fed back to a so-called empty frame task 18 via the pallets, if necessary empty boxes without containers can be fed.

As from the Fig. 1 becomes clear, the containers pass through more treatment stations on their transport route G, H, I, J than the unpacked crates on their transport route C, D, E from unpacker 3 to packer 9. In addition, there are more bottles than crates that are treated accordingly have to. For this reason, the treatment of a container from the unpacker 3 to the packer 9 takes longer than the treatment of a box from the unpacker 3 to the packer 9. The same must be taken into account when changing products from a first product in a first box to a second product with a second box .

In order to coordinate the material flows from containers, boxes or pallets, according to the present invention, a first counting device 12a-12d, 13 is provided for determining the number of containers supplied to the system. A corresponding counting device comprises at least one counter for counting the containers on the transport route from the empty container to the packer 9. For the sake of simplicity, FIGS Fig. 1 several counters 12a-d, 13 are shown, whereby one counter would actually be sufficient, but the provision of several counters improves the possibilities for coordination and measurement accuracy in the entire filling process.

It is possible that the number of containers supplied is already recorded in the area of the empties posting, in that the number is determined on the basis of the number of supplied pallets and the number of pallet layers. This gives the number of boxes loaded on a pallet and the number of containers. The pallet layers can be counted in the area of empties, for example by sensors such as light barriers or camera systems, etc.

It is also possible to count the number of containers in the area of the depalletizer, the depalletizer being connected to a first counter, for example, whereby signals can be generated during depalletizing, for example when lifting the pallet or emptying the pallet in layers, on the basis of which the counter is used can count the containers, whereby it was entered in advance how many containers per box and how many boxes per pallet.

Preferably, however, the number of containers is additionally or alternatively counted in or after the unpacker 3 via a counter 12a. The count is more precise here, as it happens that not every box is completely filled. The counter can, for example, be connected to a light barrier, but the unpacker can also generate a corresponding signal when a container is unpacked, which signal is sent to the counter 12a in order to fill the containers that come in one after the other. The system can also have a new glass feed 20 which feeds new glass into the system. A counter 12b is preferably provided here, which counts the number of containers fed in. The containers are preferably lifted from a new glass pallet in layers at the new glass feed and pushed or placed onto a container conveyor. The number of containers in such a layer is known and can therefore be counted using the number of layers. However, a counter (not shown) can also be provided in the area of the cleaning machine 6, i.e. in or after the cleaning machine. A corresponding counter 12c can also be provided in the area after or in the filling machine 7, as well as in the area of the labeling machine, i.e. in or after the labeling machine. The counters can either be connected to the corresponding treatment stations which, during their function, generate signals on the basis of which the first counting device can count the containers. However, the meters can also have other measuring devices, e.g. light barriers.

The further a counter is arranged on the transport route in the direction of the packer 9, the more accurate the measurement, since losses (eg breakage) are automatically taken into account at the end of the entire transport route, ie for example in the transport direction behind the labeling machine. For example, the number of containers supplied is relative at the beginning of the transport route determined, for example in the area of the transport routes G, H or I, the detected number of containers can be corrected with a correction value, in particular empirically determined. This means that a comparison of the number of containers recorded with a counter is compared with the number of containers determined, for example, after the labeling machine or after emptying the filler, and a loss can be determined from the difference, which can be taken into account in subsequent processes, in particular evaluated statistically and then can be used to correct the counted container numbers with the empirical loss values (manually or automatically).

The system also has a second counting device for determining a number of crates which have been fed to the packer. For this purpose, a corresponding counting device has at least one counter. For the sake of simplicity, the in Fig. 1 Example shown several counters are shown. For example, a counter 15a can be provided in the area of the empty container, ie in or after the empty container, wherein the number of boxes can be counted by a counter 15a via the number of pallets placed and the number of boxes provided on a pallet.

As also described in connection with the containers, the depalletizer can also have a counter 15b or a corresponding counter can be arranged downstream of the depalletizer, which counts the incoming pallets and can calculate the number of boxes if it is known how many boxes are loaded on a pallet is.

It is also possible that a counter 15c is arranged in the area of the unpacker 3, i.e. in or after the unpacker or in the area of the subsequent treatment stations, here for example in or after the crate washer (not shown). A counter 15e can also be provided in the area of the box distribution switch 5, which counter counts how many containers are passed on to the packer 9. A corresponding counter could also be provided on the packer. The second counting device can also have a counter 15e in or after the box distribution switch 5, which counts how many containers have been discharged from the distribution switch 5 onto the transport path F past the packer 9.

The counters can, for example, as already described above, have measuring devices, such as light barriers, for counting the containers passing through. As also described in connection with the container, the counters can also be connected to the treatment stations or to the unpacker, depalletizer or empties feeder, with function signals being emitted by the corresponding modules that serve as the basis for counting. Even if not shown, it can be empty on the transport route Crates, a crate inspection device can also be provided, which ejects defective crates, the number of the ejected crates being counted here too and being able to be used by the calculation device.

The system can have buffer sections for better coordination of the material flows. In particular, the transport routes for the crate transport must be at least long enough, or constructed as a corresponding accumulation route, that the number of crates that can be transported on this route corresponds at least to the number of crates that have space on a pallet.

On the transport route B, C, D, E, M or B, C, D, F from the depalletizer to the palletizer 11, several separating devices 19, for example in the form of mechanical separating devices, are provided, in particular box stoppers that prevent different boxes from opening up . Corresponding separation devices are also provided for the containers on their transport route G-J.

When changing products, ie when switching production from the first container in a first box to a second container in a second box, since there are still containers of the first type on the transport route G, H, I, J, the empty boxes must first be passed through the Distribution switch 5 and the transport path F are discharged. As will be explained below, the empty crates of the second type are then only forwarded to the packer after the distribution switch 5 has forwarded the last first crate to the packer. At the end of the production of the second containers in the second boxes, however, the boxes discharged at the start of production are missing and then have to be fed to the system as empty second boxes via the empty frame feeder 18. Since it is known by the first and second counting devices with the corresponding counters how many containers have been supplied to the system or how many boxes have been supplied to the packer, a calculation device 17 can be used to calculate how many empty containers on the basis of the first and second counting devices Boxes for the determined number of supplied containers still have to be supplied so that each container can actually be packed.

The calculation device 17 can be connected to a control device or to a display, for example a mobile display or a display, the display then showing an operator, for example, how many empty boxes still have to be fed in via the empty frame tasks at the end of the process. The computing device 17 can, however, also forward signals directly to a controller, which then controls a transport device that automatically transfers empty boxes on pallets to the empty frame task 18 and on to the Distribution switch leads to the packer, the depalletizer 10, the distribution switch 5 and the packer 9 being controlled accordingly.

The device also optionally has a crate sorter 40, preferably here between depalletizer 10 and unpacker 3. Sorting means that crates are inspected and crates with, for example, wrong bottles or missing bottles, or crates that cannot be unpacked, are recognized and sorted become. In the sorting process, the crates are then handled automatically or manually, e.g. foreign bottles are removed, correct bottles are inserted, bottles lying on top are removed, etc. The finished crates are then fed in again automatically or manually. Here, too, the boxes discharged and smuggled in can be counted using counters (not shown) and the count values taken into account as described.

The method according to the invention is described below with reference to Fig. 2-13 explained in more detail.

In Fig. 2 the thick arrows represent the product flow of the first container or the first container in the first boxes. The thin arrows represent the product flow of the second container or the second container in the second boxes. The thick broken arrows represent the product flow of the first empty boxes, the thin dashed arrows represent the product flow of empty second boxes. Empty transport routes are shown with dots.

Fig. 2 shows the system in a state in which the first containers are just being produced in the first boxes. Here, the depalletizer 10 is supplied with the remaining first boxes filled with empty containers on pallets for depalletization. There are still boxes filled with empty containers on the transport path B, are unpacked by the unpacker 3 and, if necessary, uncorked and treated in the treatment stations 6, 7 and 8, the finished containers being fed to the packer 9. The boxes filled with completely filled first containers are then fed to the palletizer 11 via the transport path M via the path K, for example via a binder and a pallet labeling machine, and guided out of the system to a full pallet sink. The empty first crates washed by the crate washer 5 are passed to the packer 9 via the distributor switch 5. Now it is time to switch to a second product, ie to a second container in a second box. The empty second container is already fed to the empty container in second boxes on pallets and conveyed on the transport path A to the depalletizer. Pallet tracking (eg shift register) knows where pallets with first or second boxes are located.

As in particular also from Fig. 3 is shown, so the second containers are fed in pallets in second boxes via the empties feeder and travel to the depalletizer 10. In the meantime, the last first boxes have left the depalletizer 10. In the meantime, therefore, for example, already empty first boxes can be conveyed from an empty frame task 18 to the depalletizer 10, with FIG Fig. 3 For example, a pallet with empty first boxes is already being transported to the distribution switch 5, but is stopped at the distribution switch 5, since the first empty boxes are still being conveyed from the box washer 4 via the distribution switch 5 to the packer 9.

How out Fig. 4 shows, the last first box was unpacked by the unpacker 3. The unpacker gives a signal to the depalletizer 10 to indicate that the last box has been unpacked. The depalletizer 10 can now begin depalletizing the second boxes filled with the second containers, which are transported further on the transport path B. Here, for example, two empty pallets with the first boxes were depalletized and driven to unpacker 3. This means that the rest of the first containers in the first boxes are still running through the treatment stations 6, 7, 8, 9, 11, 22, 23, while the second containers are already being fed into the system in second boxes. The distributor switch 5 still stops empty crates from the empty frame feed 18 and the depalletizer 10 and only lets the first empty crates from the crate washer 4 in the direction of the packer 9.

In Fig. 5 the second boxes with the empty second containers now already reach the unpacker 3. The last first box from the unpacker has now left the distribution switch 5 in the direction of the packer 9. Now the box distributor 5 sends a signal to the depalletizer 10, which depalletizes further empty first crates from the empty frame feeder 18. The distribution switch 5 is switched to empty crates that have been delivered from the empty frame feeder 18 via the depalletizer 10.

How out Fig. 6 As can be seen, the empty first boxes transported via the empty frame task 18 are now fed to the packer 9 via the distribution switch 5.

The calculation device 17 has already calculated for the first containers in the first boxes how many empty boxes must also be fed to the system at the end of production via the empty frame feed in order to compensate for the number of boxes ejected at the beginning of production. For this purpose, the first counting device has determined the number of containers supplied to the system via a counter, for example via a counter 12a after the last first container has been unpacked, and / or with one or more of the other counters 12b, 12c, 12d, if in each case here the last container has passed the counter. There the ejected containers (for example from a bottle inspection device 14) that have been counted can be withdrawn. The determined value can also be corrected by an empirically determined or a statistically determined correction value.

Furthermore, the second counting device, for example the counter 15d, can determine how many boxes have been fed in the direction of the packer 9, for example when the last first box has passed the counter. From this it can be determined how many additional boxes have to be additionally guided to the packer via the empty frame task 18 via the distribution switch 5 so that all the containers can be packed. The determined number of bins is how out Fig. 6-8 is shown, then fed to the packer 9. It can also be determined and displayed how many pallets still have to be fed to the empty frame feeder 18 at a certain point in time ( Fig. 6 ). This can be displayed or, as described above, can be done automatically.

The prerequisite for the treatment and subsequent further transport of the new type of pallets / boxes / containers is that a necessary changeover of the treatment station to the new type has taken place - if necessary. This information can be confirmed by the operator, for example by pressing a button or can also be recorded automatically.

In Fig. 7 new glass containers of the second type are fed to the cleaning machine. It is also possible for the new glass containers to be fed to a container rinser (not shown) which is located directly in front of the filler.

Also in Fig. 7 the depalletized second boxes filled with empty second containers were already driven to unpacker 3. How out Fig. 8 emerges, these are then also unpacked and the second boxes led to the crate washer 4 and the containers directed towards treatment stations 6,7,8 here cleaning machine, with a separating element being provided in the cleaning machine to stop the container in order to prevent it mixing of the first and second containers occurs. However, the empty second boxes from the box washer 5 are dammed up in front of the distribution switch 5 via a separating element.

How out Fig. 9 As can be seen, the last empty first box has now passed the distribution switch 5 and has been transported towards the packer. How out Fig. 9 it can be seen, if the buffer section B in front of the unpacker 3 is free for at least one pallet, the depalletizer 10 can depalletize further pallets from the empty container 2, which are then driven towards the unpacker. The empty second boxes from the box washer 5 are not fed to the packer 9, since here the empty first boxes are still being transported on the route E and, beyond that, there are no finished second containers available for the packer 9. However, the second boxes that bypassed the packer 9 by the packer on the route F are accumulated in front of the palletizer by a separating device, since the first fully filled boxes are still being palletized. In the meantime, the second containers can already be fed to the treatment stations one after the other.

Out Fig. 10 it can be seen that the last first box is moved and palletized via the distribution switch 5 to the packer 9 and then to the palletizer. It is possible that, when the last container has been unpacked from the unpacker, additional new glass is fed in via the new glass feed 20.

How out Fig. 11 As can be seen, the last first boxes filled with full containers move from the packer 9 to the palletizer 11, and an incomplete remaining pallet can move out of the system. Excess first boxes can, for example, empty to the palletizer 11 or can be ejected from the transport path, for example by means of operator intervention or automatically. Well, how out Fig. 12 it can be seen that the second empty boxes transported on the route F and D by separating elements are fed to the palletizer 11 and placed on pallets and removed from the system, but without being bound or labeled, after which these empty second pallets at another Product change can be fed back to the empty frame task 18 at the end of the process. It is possible and advantageous that a counting device 15d has determined the number of crates that have been discharged via the distribution switch.

Fig. 13 shows that after the second containers have been filled by the labeling machine, the distributor switch 5 is now switched over and the empty second boxes are passed from the crate washer 5 to the packer 9 so that the second containers can be packed into the second boxes. The switch 5 for transporting the empty second boxes from the box washer can only be switched when there are no more empty boxes in the transport section E and only so many boxes can be fed to the packer 9 that there is no blockage before packing can begin. How out Fig. 13 is shown, the second fully filled containers are now packed and the process is repeated when a third product is to be filled, at the end of the production of the second container in the second boxes, as described above in connection with the first boxes, with the Calculation device 17 determines how many empty boxes at the end of production in addition to the Empty second boxes that have already been delivered to the packer must be fed to the packer, and the corresponding action is taken.

Fig. 14 shows the method according to the invention again simplified according to an embodiment. For example, certain counters, for example counters 12a or 12b, can be used to determine how many containers were supplied to the system during the production of a certain product. The counts are advantageously carried out when the last container has passed through the measuring device or the counter. In addition, it is determined how many containers have been discharged from the system, for example via the counter 13. The counting device can then determine how many containers have been fed to the system in total.

In addition, the second counting device can be used to determine how many boxes are fed to the packer. It can either be determined, for example, how many boxes are fed into the system, for example via the counter 15a on the empty frame feeder 2, and how many boxes are ejected, in particular at the start of production, for example via the counter 15d or, if necessary, also ejected. Signals corresponding to the number of containers supplied to the system and the number of boxes supplied to the packer are then passed to the calculation device 17, which then calculates how many boxes are still missing so that all supplied containers can be packed. Since the boxes are fed in on pallets, the number of pallets can be determined. A corresponding number of boxes or pallets can then be supplied via an empty frame feed 18 for receiving empty boxes. A display can show the operator how many pallets must be fed to the empty frame feed. If pallets have already been conveyed beforehand via the empty frame task 18 to the depalletizer 10 on route Q or to the transport route P between the depalletizer 10 and the distribution gate 5 (automatically via a transport device controlled by a control or manually) before the calculation was carried out, this number can also be selected via a counter 24 and / or 16 on the depalletizer and / or on the empty frame task 18 can be counted and taken into account in the calculation or display, as is clear from the dotted line 14.

Instead of counting the crates supplied and removed in the second counting device, it is also only possible to use a counter 15e after the distribution switch to count how many crates have been supplied to the packer. The count should then take place after the last box has passed counter 15e.

Claims (20)

1. System (1) for filling containers,
   comprising:

   an empty container feeder (2) via which the system (1) can be fed with crates of empty containers, preferably on pallets, in order to refill said containers,

   an unpacker (3) which removes the containers from the crates,

   at least one treatment station (6, 7, 8) for the containers, in particular for cleaning and filling the containers, at least one treatment station, in particular a crate washer (4) for the crates,

   a packer (9) to which the treated containers and the empty crates can be fed for packing the containers into the crates, and

   a crate flow divider (5) which can feed the empty crates to the packer (9) or can discharge them from the system (1),

   characterised in that the system (1) also comprises the following components:

   a first counting device (12a-d, 13) for determining the number of containers fed to the system,

   a second counting device (15a-e) for determining a number of crates directed to the packer (9),

   a calculating device (17) which, based on signals from the first and the second counting device (12a-d, 13, 15a-e), can calculate how many crates still have to be fed for the determined number of fed containers, wherein the system is configured so that, when production is switched from first containers in first crates to the production of second containers in second crates, feeding of the second containers in the second crates starts when there are still first containers and first crates in the system.
2. System according to claim 1, characterised in that the second counting device (15a-e) comprises at least one counter for determining the number of crates fed, wherein the at least one counter (15a-e) is preferably arranged in the region of the empty container feeder (2) and/or in the region of the depalletiser (10) and/or in the region of the unpacker and/or in the region of the crate flow divider (5) up to the region of the packer (9), and preferably at least one second counter (15d, e) for determining the number of the empty crates that are discharged by the crate flow divider (5).
3. System according to claim 1 or 2, characterised in that the first counting device (12a-d, 13) comprises at least one counter (12a-d) for counting the containers fed, wherein the at least one counter, when viewed in the transport direction, is preferably arranged downstream of the unpacker (3), and the first counting device (12a-d, 13) preferably comprises at least one second counter (13) which can determine a number of removed containers.
4. System according to at least one of claims 1 to 3, characterised in that the number of containers fed, which is recorded by the at least one first counter, can be corrected by the calculation device (17) by means of a correction value, in particular an empirically determined correction value.
5. System according to at least one of claims 1 to 4, characterised in that the calculation device (17) can send signals to a display, in particular to a mobile reporting system, which indicates how many empty crates or pallets are still to be fed to the system and/or sends signals to a control unit that controls a transport device via which the empty crates can automatically be fed to the system.
6. System according to at least one of claims 1 to 5, characterised in that holding regions are provided for the crates on the transport path to buffer the crates, in particular between the empty container feeder (2) and a depalletiser (10) and/or between the depalletiser (10) and the unpacker (3) and/or between the crate washer (4) and the crate flow divider (5) and/or between the crate flow divider (5) and the packer and/or between the depalletiser (10) and the flow divider and/or an empty frame feeder (18) and a depalletiser (10) and/or between the packer and the depalletiser (11).
7. System according to at least one of the preceding claims, characterised in that a depalletiser (10) is provided between the empty container feeder (2) and the unpacker (3), and a depalletiser (11) is arranged downstream of the packer (9), and the empty crates discharged by crate flow divider (5) can be fed to the palletiser (11) via a transport path (F).
8. System according to at least one of the preceding claims, characterised in that there is a plurality of separating devices (19), in particular crate stoppers, on a transport path from a depalletiser to a palletiser (11).
9. System according to at least one of claims 1 to 8, characterised in that there are separating devices for the containers on the transport paths for holding the containers, and the system preferably comprises a new glass feed (20), wherein the new glass container flow can be held back by a separating device.
10. System according to at least one of claims 1 to 9, characterised in that function signals are passed from at least one of the treatment stations to the corresponding counter for counting the containers or crates, wherein, in particular, the depalletiser (10) is connected to the second counting device (15b, 16), wherein signals can be generated during depalletising on the basis of which the second counting device counts the crates.
11. Method for filling containers, in particular with a system (1) according to at least one of claims 1 to 10, in which method the production of a first container in a first crate is switched to the production of a second container in a second crate using the following steps:

    after the last first crate has been fed to the system,

    feeding and unpacking second crates with second containers;

    treating the second containers and the second crates separately in at least one treatment station (6, 7, 8, 4) in each case,

    packing the finished second containers in empty second crates in a packer (9),

    characterised in that

    the feeding of the second containers in the second crates starts when there are still first containers and first crates in the system, wherein

    at the start of production of the second containers, second crates are first discharged via a crate flow divider (5) and then the crate flow divider (5) switches over and subsequent second crates are fed via the crate flow divider (5) to the packer (9) in which the treated second containers are packed,

    at the end of the production, the number of second containers that were fed to the system during production is determined and

    the number of second crates fed to the packer (9) is determined, wherein it is calculated how many empty second crates still have to be fed for the determined number of fed second containers.
12. Method according to claim 11, characterised in that the number of crates fed to the packer (9) is determined by either
    counting the number of second crates that have been fed to the system and
    subtracting from that a number of second crates removed from the system upstream of the packer (9) or
    a number of second crates that are fed from the crate flow divider (5) to the packer, and, in particular, a number of the second crates that were fed to the system being counted at the same time.
13. Method according to claim 11 or 12, characterised in that at the end of production, second empty crates are fed to the system via an empty frame receiver (18), in particular on pallets, and the calculated number of second crates is fed to the packer (9) so that all the containers can be packed and any second crates fed in excess can be discharged from the system or run through the packer empty, and, in particular, at the end of production, it is calculated how many empty second crates still have to be fed to the system via an empty frame receiver (18) for the determined number of containers so that all the containers can be packed, and a corresponding number of pallets is determined and fed via the empty container feeder (18).
14. Method according to at least one of claims 11 to 13, characterised in that the number of crates fed is determined in the region of the empty container feeder (2) and/or in the region of a depalletiser (10) and/or in the region of the unpacker (3) and/or in the region of the empty frame feeder (18), and/or the number of fed containers is preferably counted of the unpacker (3) in the transport direction.
15. Method according to at least one of claims 11 to 14, characterised in that the crates discharged by the crate flow divider (5) are fed to the palletiser.
16. Method according to at least one of claims 1 to 15, characterised in that separating devices (19) are actuated and hold the second crates in order to prevent the first and subsequent second crates from colliding, and/or separating devices which prevent the first and second containers from mixing.
17. Method according to at least one of claims 11 to 16, characterised in that the transport path between the flow divider (5) and the palletiser (11) is at least long enough that the number of crates that can be transported on this path is at least the number of the second crates that fit on one pallet.
18. Method according to at least one of claims 11 to 17, characterised in that second new glass containers are fed, in particular in the inlet to a cleaning machine, before the second containers are fed from the unpacker to the cleaning machine.
19. Method according to at least one of claims 11 to 18, characterised in that the second containers pass a labelling machine (8) downstream of a filler (7) and the number of second containers fed is counted after the labelling machine has run idle on or downstream of the labelling machine, and the corresponding number of second crates that is required to pack all the containers is calculated, wherein, in particular, missing second crates are fed to the packer and excess crates are removed via the flow divider.
20. Method according to at least one of claims 11 to 19, characterised in that the second containers or crates are treated in a treatment station only if the corresponding treatment station has first been switched to the second containers or crates, if necessary.

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