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Bottles sorting and
    packaging
Activity Area
•   Germany
•   Austria
•   Czech Republic
•   Slovakia
•   Romania
•   Hungary
Western Europe
Germany
• KÖNIG PILSNER, Kulmbach: packaging and selling 20,000,000 NRW bottles, filling
   ALE bottles
• Bitburg sorting 110,000,000 bottles, filling 45,000,000 new bottles, packaging
   40,000,000 used NRW-bottles
Austria
• EGGER Brewery, St. Pölten: changing 13,000,000 NRW bottles
• STIEGEL, Salzburg: changing 20,000,000 NRW bottles
• STEIER BRAU, Graz: changing and sale of 15,000,000 0,33 VICHY bottles
• ZIPFER, Zipf: changing 56,000,000 NRW bottles
Central and Eastern Europe
Romania
•   BRAU UNION Craiova: packaging 22,000,000 NRW bottles and BOSMANN filling
•   URSUS Breweries SA: packaging 18,000,000 GOLD bottles

Czech Republic
•   SABMiller - Plzensky Prazdroj: packaging 20,000,000 NRW (2006)
•   SABMiller - Plzensky Prazdroj: packaging 34,000,000 NRW (2007)

Slovakia
•   Heineken Slovensko - packaging 18,000,000 NRW bottles (2007)
•   SABMiller - Pivovar Šariš - packaging and sale of 10,000,000 NRW bottles (on-going project)
Hungary
•   BRAU UNION, Sopron - packaging and selling 24,000,000 NRW bottles (2003)

•   BRAU UNION, Sopron - packaging and sale of 39,000,000 NRW bottles, BOSMANN
    filling (2005),

•   DREHER Budapest - packaging and sale of 14,000,000 NRW bottles (2005)
Germany actual
Sirl Munich, 90 Mio. € yearly with beverage logistic
•   Permanent sorting 7-ways, full-automatic bottle out-taking, selection-in-taking

•   Full-automatic de-palletizer

•   Sorting of bossing-branded bottles

•   125.000 bottles each shift
Germany actual
Trinks Berlin, biggest beverage wholesaler in Germany
•   Permanent sorting 4-ways, full-automatic bottle out-taking, selection-in-taking

•   Permanent palletizing used bottles industrial

    standard

    Sorting of UV-stabilisized white glas

    Sorting of bossing – branded bottles

•   75.000 bottles each shift
Operation steps


•   1) Removal of NRW bottles from the crates and industrial packaging

•   2) Filling new bottles into the crates

•   3) Sorting of the bottles
1) NRW removal and packaging
•   Generally, beer bottles arrive on EURO palettes (height of 5 crates), a layer
    contains 8 crates.

•   In one step, 160 beer bottles can be lifted and placed on the sorting table, sorting
    is done manually.

•   NRW bottles are stacked on the 1000 x 1200 industrial palettes (1904 bottles /
    pallet).

•   The size is1000 x 1200 x 2050 mm and weight is 720-750 kg.
Operation steps

1) Removal of NRW bottles from the crates and industrial packaging

2) Filling new bottles into the crates

3) Sorting of the bottles
•   Plastic or cardboard-based separator sheets are used

•   The stack is fixed with UV-resistant stretch foil

•   The palettes can be stored in the storage area up to two stacks in height: 2 x 1904

    / 1.4 m2 = 2,720 units / m2

•   The space required for the technology is 40 m2.

•   Package can be loaded several times, so for example one truck from the pant to

    storage, second truck after a while to customer
2) Filling new bottles into crates

•   Empty crates are placed manually on the loading unit
•   The unloader and the loader machines shall be installed closely, so crates emptied can be
    filled immediately with new bottles.
•   Forklifts will be used to deliver the new beer bottles to the filling machine.
•   The performance of the loading machine is geared to that of the removing unit.
•   Separator sheets and industrial pallets that become available after loading the new beer
    bottles can be used for packaging the used NRW.
Requirements
•   Comprehensive material handling with forklift trucks

•   Comprehensive energy and LPG supply

•   Usage of amenities

•   Person dedicated to handle the responsibilities of communication

•   Capacity conciliation on a daily and weekly basis
Energy and material requirements
•   stretch foil
•   separator sheets (plastic or cardboard)

•   pallets

•   Compressed air, 120 litres/min and 6 bar operating pressure. If not available, a
    compressor (30 kW ) shall be installed next to the machine.

•   The energy required by the machine is below 10 KW.
Overview example
                   1   3/8 lines packing bottles from crates


                   2   recognize bottles

                   3   3-12 sorting lines


                   4   selective packer of bottles in crates

                       Selective control of crates
                   5   transportation, optional direction of
                       crates is direction of bottles


                   6   Bottles palettizer
Components
 3-8 crates/step
bottles taking out
              1.200 - 2.400 crates/hour
              Energy 4-6 KW
              6 Bar
              20l-40l/min
Components
Recognition of bottles,

                Speed up to 12 bottles /sec
                Recognize rate > 99%
                Blind out bad tees
                Storage: 6 Mio. pictures
                Recognize:
                - UV-protected white bottles.
                - Bossing
                - different colour and shape.
                Gate to any number of bottle lines.
Components
 Sorting line

            Line-greasing
            Expandable to any number of sorting
            lines.

            Realtime Information Management ,
            so you get information about the
            mixery and so you can tweak the
            bottle-gates, also check the effency
            and record incoming trucks
components
Selective bottle packaging, clever logistic system

                             1.200 – 2.800 crates/hour
                             5 KW
                             6 Bar
                             30l-70l/min

                             Optional are the crates-lines under
                             the packer, moving in the same
                             direction of the bottles for easy
                             logistic
Components
Bottles packaging
             20.000 Bottles / hour
             6 KW
             6 Bar
             120l/min
             Packaging industry-standard

             Package can be loaded several times,
             so for example one truck from the
             pant to storage, second truck after a
             while to customer
FAKTOR GmbH
   Spinnereiinsel 3D
D-83059 Kolbermoor
Tel +49 8071 93120
 Fax +49 8071 93122
    www.faktor.de

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Bottles sorting and packaging

  • 2. Activity Area • Germany • Austria • Czech Republic • Slovakia • Romania • Hungary
  • 3. Western Europe Germany • KÖNIG PILSNER, Kulmbach: packaging and selling 20,000,000 NRW bottles, filling ALE bottles • Bitburg sorting 110,000,000 bottles, filling 45,000,000 new bottles, packaging 40,000,000 used NRW-bottles Austria • EGGER Brewery, St. Pölten: changing 13,000,000 NRW bottles • STIEGEL, Salzburg: changing 20,000,000 NRW bottles • STEIER BRAU, Graz: changing and sale of 15,000,000 0,33 VICHY bottles • ZIPFER, Zipf: changing 56,000,000 NRW bottles
  • 4. Central and Eastern Europe Romania • BRAU UNION Craiova: packaging 22,000,000 NRW bottles and BOSMANN filling • URSUS Breweries SA: packaging 18,000,000 GOLD bottles Czech Republic • SABMiller - Plzensky Prazdroj: packaging 20,000,000 NRW (2006) • SABMiller - Plzensky Prazdroj: packaging 34,000,000 NRW (2007) Slovakia • Heineken Slovensko - packaging 18,000,000 NRW bottles (2007) • SABMiller - Pivovar Šariš - packaging and sale of 10,000,000 NRW bottles (on-going project)
  • 5. Hungary • BRAU UNION, Sopron - packaging and selling 24,000,000 NRW bottles (2003) • BRAU UNION, Sopron - packaging and sale of 39,000,000 NRW bottles, BOSMANN filling (2005), • DREHER Budapest - packaging and sale of 14,000,000 NRW bottles (2005)
  • 6. Germany actual Sirl Munich, 90 Mio. € yearly with beverage logistic • Permanent sorting 7-ways, full-automatic bottle out-taking, selection-in-taking • Full-automatic de-palletizer • Sorting of bossing-branded bottles • 125.000 bottles each shift
  • 7. Germany actual Trinks Berlin, biggest beverage wholesaler in Germany • Permanent sorting 4-ways, full-automatic bottle out-taking, selection-in-taking • Permanent palletizing used bottles industrial standard Sorting of UV-stabilisized white glas Sorting of bossing – branded bottles • 75.000 bottles each shift
  • 8. Operation steps • 1) Removal of NRW bottles from the crates and industrial packaging • 2) Filling new bottles into the crates • 3) Sorting of the bottles
  • 9. 1) NRW removal and packaging • Generally, beer bottles arrive on EURO palettes (height of 5 crates), a layer contains 8 crates. • In one step, 160 beer bottles can be lifted and placed on the sorting table, sorting is done manually. • NRW bottles are stacked on the 1000 x 1200 industrial palettes (1904 bottles / pallet). • The size is1000 x 1200 x 2050 mm and weight is 720-750 kg.
  • 10. Operation steps 1) Removal of NRW bottles from the crates and industrial packaging 2) Filling new bottles into the crates 3) Sorting of the bottles
  • 11. Plastic or cardboard-based separator sheets are used • The stack is fixed with UV-resistant stretch foil • The palettes can be stored in the storage area up to two stacks in height: 2 x 1904 / 1.4 m2 = 2,720 units / m2 • The space required for the technology is 40 m2. • Package can be loaded several times, so for example one truck from the pant to storage, second truck after a while to customer
  • 12. 2) Filling new bottles into crates • Empty crates are placed manually on the loading unit • The unloader and the loader machines shall be installed closely, so crates emptied can be filled immediately with new bottles. • Forklifts will be used to deliver the new beer bottles to the filling machine. • The performance of the loading machine is geared to that of the removing unit. • Separator sheets and industrial pallets that become available after loading the new beer bottles can be used for packaging the used NRW.
  • 13. Requirements • Comprehensive material handling with forklift trucks • Comprehensive energy and LPG supply • Usage of amenities • Person dedicated to handle the responsibilities of communication • Capacity conciliation on a daily and weekly basis
  • 14. Energy and material requirements • stretch foil • separator sheets (plastic or cardboard) • pallets • Compressed air, 120 litres/min and 6 bar operating pressure. If not available, a compressor (30 kW ) shall be installed next to the machine. • The energy required by the machine is below 10 KW.
  • 15. Overview example 1 3/8 lines packing bottles from crates 2 recognize bottles 3 3-12 sorting lines 4 selective packer of bottles in crates Selective control of crates 5 transportation, optional direction of crates is direction of bottles 6 Bottles palettizer
  • 16. Components 3-8 crates/step bottles taking out 1.200 - 2.400 crates/hour Energy 4-6 KW 6 Bar 20l-40l/min
  • 17. Components Recognition of bottles, Speed up to 12 bottles /sec Recognize rate > 99% Blind out bad tees Storage: 6 Mio. pictures Recognize: - UV-protected white bottles. - Bossing - different colour and shape. Gate to any number of bottle lines.
  • 18. Components Sorting line Line-greasing Expandable to any number of sorting lines. Realtime Information Management , so you get information about the mixery and so you can tweak the bottle-gates, also check the effency and record incoming trucks
  • 19. components Selective bottle packaging, clever logistic system 1.200 – 2.800 crates/hour 5 KW 6 Bar 30l-70l/min Optional are the crates-lines under the packer, moving in the same direction of the bottles for easy logistic
  • 20. Components Bottles packaging 20.000 Bottles / hour 6 KW 6 Bar 120l/min Packaging industry-standard Package can be loaded several times, so for example one truck from the pant to storage, second truck after a while to customer
  • 21. FAKTOR GmbH Spinnereiinsel 3D D-83059 Kolbermoor Tel +49 8071 93120 Fax +49 8071 93122 www.faktor.de