Two in ONE: Revealing under- and overfills

In-house developed, innovative, intelligent: A new type of X-ray module provides the HEUFT ONE with an additional plus in functionality and recognition reliability. The entry-level device for space-saving full container inspection now finds not only underfilled but also overfilled containers with one and the same measuring bridge – and compensates for variations in glass thickness.  In difficult cases an exact fill level check is realized.

If there is less in it than is written on it, this may not only be a legal problem, but also really annoying for the customer. After all, he has paid for the full nominal fill quantity indicated on the label! So it’s no wonder that he feels he’s being taken advantage of and next time he’ll choose a competitor’s brand. On the other hand, bottlers don’t want to deliver an overfull full container either. After all, they don’t like to give away any of their valuable product and also want to prevent too much content from causing containers to burst during transport, at the retail outlet or at the end consumer’s home. A fill level check that identifies both under- and overfilling of the nominal fill quantity and reliably sorts out the affected primary packaging is therefore highly advisable.

This now functions in one and the same working process with only one X-ray module which can be connected to the compact HEUFT ONE as standard with immediate effect. The newly developed module alone is now sufficient in almost all cases where two measuring bridges were previously necessary in order to detect both underfilled and overfilled bottles, jars and cans: the fill level check covers the area between them completely even if there is a distance of almost 30 millimeters between the upper and lower fill limit.

Glass thickness fluctuation compensation during fill level check
Thanks to a recent extension of the self-programmed software and the new design of the X-ray receiver, the innovative measuring bridge not only performs one, but up to eight parallel measurements of the X-ray absorption of each individual packaging material – distributed over the entire height of the filling area to be inspected. Fluctuations in thickness and structures in the container glass, which in conventional one-dimensional measurement absorb X-rays to such an extent that the actual level of the contents could be overlooked, are detected by the additional measurement results and can therefore be specifically compensated for. Thus the inspection of the filling quantity delivers exact results even in difficult cases.

With the innovative X-ray measuring bridge, the reliable detection of underfilling and overfilling is also possible in non-transparent packaging materials, metal containers and full containers with special contents such as oils, powders or high-percentage alcohol –  i.e. in special cases where the use of the alternatively available high-frequency level measurement is not always possible.

An ideal introduction to the full container check at a HEUFT level
From the evaluation software for error analysis to status lights and the emergency stop switch, all important components are fully integrated in the new X-ray module, which is to be attached directly to the conveyor belt. The individual measurement results are already converted into good or bad signals there and forwarded to the compact HEUFT ONE control terminal. In this way it can be positioned flexibly in a very confined space even further away from the actual detection. The slim device is therefore the optimal solution for getting started with the full container check at a HEUFT level especially for smaller filling lines with difficult installation positions.

An intelligent colour sensor camera with a directly integrated image evaluation can be connected to the HEUFT ONE as an alternative to the new X-ray measuring bridge in order to verify best before dates, barcodes and 2D codes or article and serial numbers among other things. In each case a more complex detection unit can be combined with simpler sensor technology. In addition to underfilled, overfilled or incorrectly labelled products the compact stand-alone device finds for example unsealed full containers in one and the same operation.

Quality, safety and efficiency:  this is what matters when filling and packaging food, drinks and pharmaceuticals!  The modular solutions from HEUFT SYSTEMTECHNIK GMBH put these key factors into practice simply and effectively.  They ensure, during maximum productivity, that only perfect products reach the market.  Unique camera, X-ray and image processing technologies for a precise empty and full container inspection, trend-setting labelling technology and smart tools for container flow optimisation, production data acquisition and performance analysis safeguard product quality and line efficiency sustainably!  A consistent modular design principle with a cross-system control unit for different technologies, procedures and modules generates, together with a high component similarity, the correct automation solution for every application. 

Those who decide in favour of a user-friendly HEUFT system can depend on a high level of operational reliability.  Competent support is always guaranteed with the long-term availability of spare parts and the 24/7 on call service.    This concept keeps the globally operating company on a dynamic course of growth.  In the meantime the number of employees has long since exceeded the 1,000 mark.  Its own locations in 14 different countries and a comprehensive network of service bases on all five continents meet the huge demand for the HEUFT systems which are manufactured exclusively in Germany. The result:  more safety, quality and efficiency during the filling and packaging of food, drinks and pharmaceuticals.

For more information go to www.heuft.com

Written by Kevin Gambrill

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