UG_ME_63_120320119037

AUTOMATED BOTTLE UNSCRAMBLER
A PROJECT REPORT
Submitted By
BARAD HRISHIKESH RANJITSINH
(Enrolment No: 120320119037)
Infulfilment for theawardofthedegree
Of
BACHELOR OF ENGINEERING
In
Mechanical Engineering
L.J Institute of Engineering & Technology
GujaratTechnologicalUniversity,Ahmedabad
April 2016

LJIET Ahmedabad | GTU | Mechanical Engineering | Hrishikesh Barad 2

ACKNOWLEDGEMENT
I would like to express my deepest appreciation formy Internal Guide - Asst. Professor Mr
Kamlesh Kadia and my External Guide –MrAjay Mehta. They continuously encouraged
me for further research regarding this project and without their guidance this project might
not have been possible.
Theyhelpedme through all the thick and thins -in studies and other works. They always
providedme withthe true guidance a student needs in any of the matters. I am very thankful to
themfor providingme a huge knowledge database about everything. They always have
inspired me to innovate new things and to research about the new ideas which are necessary
in upcoming days for our country.
I express my deepest gratitude to our Head of Mechanical Engineering Department -
Mrs Aarti Patel, for encouraging me to prepare the project on “AUTOMATED BOTTLE
UNSCRAMBLER”. I take this opportunity to express my sincere gratitude to the Director of
L. J. Institute of Engineering and Technology for his valuable guidance, motivation and co-
operation with encouraging attitude at all the stages of this work.
I thank the Almighty, my guides & my friends for their constant encouragement without
which this project work would not have be possible.

PLAGIARISM REPORT

ABSTRACT
Bottles are usually manufactured and filled at two different plants. Let’s say Bottles
are manufactured at 500bpm and if we use manual labour to unscramble the bottles
for filling, the output will be 60-80bpm at max. This creates a bottleneck. In order to
remove this problem, Automation of Unscrambling process is a necessity in the
packaging line industries. The intention of this project is to create an integrated
Unscrambling machine using basic mechanical approaches. The functions to be
incorporated in our machine are Unscrambling, Orientation and Air-rinsing – All this
in a compact & user-friendly machine. The Usefulness and the Economical advantage
of the Rotary Unscrambler has a great future scope for Commercialisation.

LIST OF TABLES
Table Number Table Description
Table 2.1 Patent analysis
Table 2.2 Research Papers
Table 2.3 Market Survey Companies
Table 3.1 Components
Table 4.1 Analysis of types of Plastics
Table 4.2 Analysis of types of steels

LIST OF FIGURES
Figure number Figure Description
1.1 Vision Based Unscrambler
1.2 Linear Unscrambler
1.3 Article Positioning Machine
3.1 Phases of unscrambling
3.3 Aligner
3.4 Blower
3.5 Bottle
3.6 Hopper ISO view
3.7 Hopper top view
3.8 Hopper Autocad design
3.9 Chute ISOview
3.10 Chute side view
3.11 Turn table side &ISO view
3.12 Turn table Autocad design
3.13 Neck plate Autocad design
3.14 Turn table discs ISOview
3.15 Turn table ring
3.16 Base plate
3.17 UHMWPE ISOview cutting
3.18 UHMWPE manufacturing sheet
3.19 Hopper top view
3.20 Turn table top view
3.21 patents unscrambling machine
3.22 sectional view of hopper
3.23 Gear shaft
4.1 Delrin Properties
4.2 UHMWPE properties
4.3 SS 304 Properties
5.1 Manufactured turn table

LIST OF SYMBOLS AND ABBREVIATIONS
Abbreviation/Symbol Full form/Meaning
BPM Bottles per minute
TPE Thermoplastic elastomer
UHMWPE Ultra-high-molecular-weight
polyethylene

TABLE OF CONTENTS
College completion certificate ii
Company completion certificate iii
Acknowledgement iv
Plagiarism report v
Undertaking about originality vi
Abstract vii
List of Tables viii
List of Figure ix
List of Abbreviations x
Table of Contents xi
Chapter: 1 Introduction to Project 13
1.1 Problem Definition 14
1.2 Types of Unscramblers 16
1.3 Rotary Bottle Unscrambler 19
1.4 Advantages of Automated Unscrambler 20
1.5 Aims & Objectives 21
Chapter: 2 Research and Analysis 22
2.1 Patent Analysis 23
2.2 Research Papers 24
2.3 Market Survey 25
Chapter: 3 Working and Methodology 27
3.1 Steps involved in Unscrambling 28
3.2 Phases of unscrambling process 29
3.3 Components 30
3.4 Design 32
3.5 OldGeneral Assembly of Machine 42
3.6 NewGeneral Assembly of Machine 43
3.7 Novelty 44

Chapter: 4 Analysis of Material 45
4.1 Analysis of types of plastics 46
4.2 Analysis of types of Steels 49
Chapter: 5 Epitome of Automated Unscrambler 50
5.1 Implementation 51
5.2Limitation & Risk Factors 52
5.3Project Features & Expected Outcome 53
5.4Benchmarking 54
5.5Future Scope 55
Appendix: 1 PPR1 56
PPR2 57
PPR3 58
PPR4 59
Appendix: 2 BMC Report 60
Appendix: 3 PDE 1 62
PDE 2 65
PDE 3 69
References 70

CHAPTER 1: INTRODUCTION TO PROJECT
1.1 Problem Definition
1.2 Types of Unscramblers
1.3 Rotary Bottle Unscrambler
1.4 Advantages of Automatic Unscrambler
1.5 Aims & Objectives

1.1 PROBLEM DEFINITION
Going back 15 years, most of the bottling companies would use depalletizing
systems to introduce empty bottles to the filling line. At that time, the 500 ml water
bottles were in the 23–28 gram range. As lightweighting began in the late 1990s,
depalletizing of bottles proved to be inefficient with fallen bottles being a significant
problem. Bottle unscramblers were introduced to eliminate the problem of trying to
maintain bottle orientation off the depalletizer. With an unscrambler it didn’t matter if
the bottles fell over during the depalletizing process. From the depalletizer, the bottles
would be conveyed in mass to the unscrambler, which had the responsibility of
orienting the bottles in an upright position.
Let’s say Bottles are manufactured at 500 bpm in a Mineral bottled water
company and if they use manual labour to unscramble the bottles for filling, the
output will be 60-80bpm at max. This mismatch creates a bottleneck. Manual
Unscrambling output is a very slow tedious process. The Bottle filling plant receives
the bottles in scrambled positions and need to be properly unscrambled and oriented
before filling.
Another problem faced in Manual unscrambling is improper Hygiene and
Inconsistency in Unscrambled output is often faced while manual unscrambling of
bottles, meaning there can be problems like improper placing of bottles in upright
position or bottles falling off from the filling conveyors.
Manual unscrambling does not ensure proper handling and protection.
Despite such Limitations of Manual Unscrambling, the cost of hiringabout 15 laborers
is around 1-2lacs/month.

There is a shortage of labor due to increased literacy, which has led to a
declination of blue-collar workforce. This can be used to our advantage by assigning a
skilled worker to operate machines like Automated bottle unscrambler.
Manual Unscrambling and Orientation leads to lower production rates and
decreases Performance.Overall efficiency of the manual process is very less and cost
is higher.Manual Unscrambling Output is only 60 bpm, while automated
unscrambling output is about 600 bpm, which means that efficiency of manual
unscrambling is about 90% lesser than automated process.
Talking about the presently existing automatic unscrambling machines, the
maintenance and initial costs are high. Hang up of bottles during operation of the
drum is a characteristic of some of the presently existing systems.Air rinsing is also
not provided integrated with the common Unscrambling Machines.

1.2 TYPES OF UNSCRAMBLERS
A Bottle Unscrambler & Orienter is an automatic, variable speed packaging
machine that receives empty bottles in bulk, then orients, processes, and positions
them onto a moving conveyor for further downstream processing, like filling and
capping. There are several mechanical approaches to bottle unscrambling.
It is designed to provide oriented bottles to the production line, which means
that the bottles are positioned vertically upright in the machine before they reach the
filling line.
There are 4 types of bottle unscramblers:
• Vision Based Unscrambler
• Linear Bottle Unscrambler
• Gravity Based Unscrambler
• Rotary Bottle Unscrambler
The unscrambler I have designed with the help and support of J.P Machines and Tools
will be a Rotary Bottle Unscrambler. The limitations of the former three unscramblers
are discussed on the next page.

Limitations of:
• Vision Based Unscrambler: It consists of cameras and sensors that sense the
position and alignment of the bottles but these equipments are very costly and
increas the overall cost of the system.
• Linear Bottle Unscrambler: This unscramble is a horizontally spread
unscramble that requires lots of ground. Thus, increased floor space
requirements is a limitation of the linear unscramble. Linear air rinsing
machines have high space requirements which increases production and
assembly time.
• Gravity Unscrambler: This unscramble uses catchers and vacuum settlers that
are very costly in nature.
Courtesy of: patents.google.com
Figure 1.1

Figure 1.2
Figure 1.3

1.3 ROTARY BOTTLE UNSCRAMBLER
A rotary unscramble is used for rearranging a plurality of incoming bottles
into a stable conveyable orientation.This machine reduces human resource and can be
made automatic by using design of a Hopper and sprocket mechanism.Automated
Bottle unscrambling is a Simplistic approach to container handling.
Randomly oriented bottles are received in a bulk into the hopper and supplied
to the centrifugal rotating disc by means of a conveyor. The bottles are supplied to the
orienting unit & are set upright in a vertical position, stabilized and placed on the
conveyor.
• If the bottle arrives in the topside down position it will pass through the
orienting guides without any effect.
• If the bottle arrives in the wrong position, it will be turned 180° topside down
when it passes through the orienting guides.
• In the next phase, the bottles are air-rinsed using nozzles that are mounted
below them.
• In the final phase, the bottles are turned 180° in topside up position using
curved guides.

1.4 ADVANTAGES OF AUTOMATIC UNSCRAMBLER
• Covers minimal Workspace area
• Reduces human resources
• Automation of production process
• Rearranges bottles into a stable conveyable orientation
• Easy bottle loading
• Easy hopper access
• Output upto 500 bpm based on the speed of the motor
• High Efficiency
• Hygiene is maintained, specifically useful for pharmaceutical & food industries
• Simple Mechanism
• Suitable for large variety of bottles of different shapes and sizes
• High productivity with optimum quality
• No interruption in filling process
• Integrated function of Air rinsing
• Maximum flexibility
• Elimination of hangup of bottles
• Consistent operation
• Rotary Unscrambler is more economical
• User friendly
• Reduces Changeover Time Between Jobs
• Savings of material
• Ease of Operations
• Less maintenance

1.5 AIMS & OBJECTIVES
• Speed up the packaging processes using Automation.
• Economical and durable machine.
• Compact machine that has minimum floor space requirements.
• Multiple functions in a single machine.
• Provide large number of unscrambled containers with no interruption.

CHAPTER 2: RESEARCH & ANALYSIS
2.1 Patent Analysis
2.2 Research papers
2.3 Market Survey

2.1 PATENT ANALYSIS
Table 2.1
Publication Number Publication Date Title Learning/Remarks
US 7,258,222 B2 Aug. 21, 2007 Article positioning
machine
• Unsuccessful because
the Bottle cannot
travel on neck.
US 7,270,229 B2 Sep. 18, 2007 Container
unscrambler system
having adjustable
track and method
• Uses Adjustable
Track Method to
orient the containers
in coaxial position.
US 7,293,656 B2 Nov. 13, 2007 Adjustable sorter
disc method
apparatus and
system
• Equipped with
Sensor/Camera.
• Gives the Idea of
integrating
Unscrambling and
Rinsing processes.
US 7,735,627 B2 Jun. 15, 2010 Plastic bottle
unscrambler with
vacuum settling
tables
• Catchers used are
costly.

2.2 RESEARCH PAPERS
Table 2.2
Title Author
Design and modelling of unscrambler for bottle
packaging
SutariyaVijaybhaiBabubhai
Dynamic Performance Analysis of Conveyor
Chains under Variable Loading Environment
HU Rui-hua,MAO Li-min
Research Progress of Unscrambler and its
Application on Settling Culture Bottles
Automatically
Wang Liangju,Yang Li,ZhangTiezhong
Bottle Design, Plastic Andrea S. Mandel
Simulation of High Speed Bottle Manufacturing
Lines: Software Evaluation, Techniques and
Results
Vasudevan, Karthik

2.3 MARKET SURVEY
There is a great need of fast production in packaging line industries which
requires faster packaging processes too and an Integrated Bottle Unscrambler along
with multiple functions can serve the industries well.
Going back 15 years, most of the bottling companies would use depalletizing
systems to introduce empty bottles to the filling line. At that time, the 500 ml water
bottles were in the 23–28 gram range. As light weighting began in the late 1990s,
depalletizing of bottles proved to be inefficient with fallen bottles being a significant
problem. Bottle unscramblers were introduced to eliminate the problem of trying to
maintain bottle orientation off the depalletizer. With an unscrambler it didn’t matter if
the bottles fell over during the depalletizing process. From the depalletizer, the bottles
would be conveyed in mass to the unscrambler, which had the responsibility of
orienting the bottles in an upright position.
The targeted industries are:
• Beverage companies
• Dairy industries
• Food processing industries
• Chemical industries
• Household products’ manufacturers
• Liquor industries
• Personal care products’ companies
• Motor oil companies
• Edible oil container companies
• Pharmaceutical Industries
• Fertilizer – agro industries

Certain pharmaceutical companies require sterilized bottles, which can be fulfilled
by ionized air-rinsing during the bottle unscrambling process. Usually high-tech
vision based unscramble systems are used in such cases.
Average cost of the Unscrambling machines available is about 40 lacs which gives
an output of 500bpm, while the rotary unscrambling machine I will design with the
support of J.P Machines & tools will be more economical compared to the market
prices.
Various companies and industries that have shown interest in automatedunscrambler
machines are:
Table 2.3
Unimark remedies ltd.
Dishmanpharma ltd
ZydusCadila ltd
Amneal labs ltd
Torrent pharmaceutical ltd
Parle foods ltd
HUL
Colgate
Nirma ltd

CHAPTER 3: WORKING AND METHODOLOGY
3.1 Steps involved in Unscrambling
3.2 Phases of unscrambling process
3.3 Components
3.4 Design
3.5 General Assembly of machine
3.6 Novelty

3.1 STEPS INVOLVED IN UNSCRAMBLING
Randomly oriented bottles are received in a bulk into the hopper and supplied to the
centrifugal rotating disc. The hopper stores bottles and prevents production line overload and
disruption, using a deflector and a blower. The orienting element has a curved shape, such
that the bottle is easily released, after it has rotated beyond vertical into a substantially neck
trailing orientation.
The unscrambling process using a rotary bottle unscrambler is an automated process n
which two steps are involved in getting the output of correctly oriented bottles on the
conveyer:
As described in US7270229 the unscrambler in one embodiment comprises of an adjustable
unscrambler having a rotatable circular horizontal floor and a circular wall perpendicular and
adjacent to the circular edge of the horizontal floor creating a bowl shape. At the outer edge
of the horizontal floor, there is a plurality of individual ring members, adjacent to each other
and extending around the floor of the unscrambler, such that each ring member from the
outermost member to the innermost member, exhibits a circumference less than the adjacent
outer member. Each of the ring members is capable of individual movement in a
perpendicular direction with respect to the relatively horizontal orientation of the floor. The
movement of ring members is not completely independent of all the other concentric rings as
will be described later. The floor of the unscrambler is generally horizontal and is also
slightly domed providing a gradually sloping convex floor surface so that when the empty
containers are loaded into the unscrambler, the sloping convex surface of the domed floor
causes the empty containers to gravitate toward the outer wall of unscrambler. Centrifugal
force caused by the floor being rotated also urges the empty containers toward the outer wall
of the unscrambler and assists in maintaining them near the outer wall. Although the sloping
floor and centrifugal force causes the containers to gravitate to the outer wall of the
unscrambler, the containers may end up in a totally undesirable random orientation. In order
for the containers to move forward in orderly fashion towards the chute - which transports the
containers to another device in the packing process, or which helps in achieving co-axial
bottles. All of the containers or bottles must be in some sort of alignment so that they will
fittingly traverse the chute or conveyer without clogging the path.

3.2 PHASES OF UNSCRAMBLING PROCESS
• Input: Loading scrambled bottles on rotating disc of hopper
• Phase 1: Making the scrambled bottles on the hopper coaxial using the chute attached
to the hopper mechanism.
• Phase 2: Orienting all the bottles in topside down position using guides mechanism
• Phase 3: Air rinsing from the bottom using nozzles
• Phase 4: Orienting all the bottles in top side up position using invertor
Fig 3.1

3.3 COMPONENTS
A Rotary Bottle Unscrambler is based on a simple hopper mechanism and has
minimum number of components with ease of operations. Various components of an
automated rotary unscramble are:
Table 3.1
Component Use
Hopper Bottle storage
Taper plate Easy flow of bottles
Turntable Bottle orientation
Agitator/Aligner Avoid jamming of bottles
Fan/Blower Avoid jamming of bottles
Chute Transferring bottles from hopper to turntable
Motor Provide rotational motion to shaft
Gear Speed reduction
Cams Forms the frame and support of machine
Guides Inverting and orientation process

Figure 3.2 Fig 3.3
Fig 3.4
Different types of plates:
• Base plate
• Supporting plate
• Neck plate
• Rotating disc

3.4 DESIGN
The automated Rotary bottle Unscrambler I will be producing, will be designed for an
output of approximately 120 bpm. The dimensions of the bottle are
Length = 75mm
Radius = 30mm
Figure 3.5

3.4.1 DESIGN – HOPPER
Fig 3.6
Fig 3.7
• This is the component where bottles are stored and loaded manually or by using an
automatic conveyor.
• It consists of two rotating discs, a blower and a taper.
• The UHMWPE rotating disc’s diameter is 703 mm while SS rotating base plate’s
diameter is 788
mm.
Fig 3.8

3.4.2 DESIGN – CHUTE
Fig 3.9
• The bottles from the hopper are transferred to the mouth of the chute and the output is
co-axial bottles at the bottom end of chute.
• It is made up of just four bent rods with minimal material requirement.
• The chute is designed such that the bottles can smoothly travel through it.
Fig 3.10

3.4.3 DESIGN – TURN TABLE
Fig 3.11
• As explained earlier, phases – 2,3,4 are completed using this turntable assembly
consisting of multiple discs, plates, motor and a two-stage gear box.
• The neck plate, base plate and rings are made of SS 304.
• The outer diameter is 580 mm while inner diameter is 450 mm.
• The white discs shown above are made from Ultra high molecular weight poly
ethylene.
Fig 3.12

3.4.4 DESIGN – NECK PLATE
Fig 3.13
• The neck plate consists of C shaped slots to accommodate only the neck of the bottle
while it is in topside down position. Thus the diameter of C shaped slots is slightly
lesser than 33 mm.
Fig 3.14

3.4.5 DESIGN – BASE PLATE
Fig 3.15
Fig 3.16

3.4.6 DESIGN – UHMWPE DISCS
Fig 3.17
In order to reduce material wastage, the UHMW Polyethylene discs used in the
turntable are cut from one sheet of UHMW and then assembled using nut-bolts. This
saves a lot of material and reduces overall cost.
Fig 3.18

Figure 3.20
Figure 3.19
So, 18 bottles can be fitted in the periphery of the disc after preserving the space for aligner-
blowers and the bottle chute.

Figure 3.21
Figure 3.22 Courtesy of patents.google.com

3.4.7 MOTOR & GEAR BOX SPECIFICATIONS
• Motor used: Standard 0.5 BHP - 1440 rpm - Four pole - Three phase - 440 Volt
• Total number of slots in turntable: 24
• Usable slots for final output: 18
• Final output required: 18 x 10 rpm = 180 bottles per minute
• For >140 gear ratio, either helical gears or two-stage gearboxes are used. Since helical
gears are costly, we have used the Two stage gear reduction box:
• First stage gear reduction process reduces the rpm from 1440 to 72 rpm using gear
ratio 20:1
• Second stage gear reduction process reduces the rpm from 72 to 10.28 rpm using gear
ratio 7:1
Gear box
Main-shaft Fig 3.23

3.5 OLD GENERAL ASSEMBLY OF MACHINE
A figure of the general assembly of entire rotary unscrambling machine generated in
Autocad Software in 7th
semesteris shown below:
Figure 3.24

3.6 NEW GENERAL ASSEMBLY OF MACHINE
Front View
Fig 3.25
Right hand side
view
Fig 3.26

3.7 Novelty
Our main aim is to integrate two useful processes or functions of Bottle
Unscrambling and Air rinsinginto one machine.
For this, all the bottles are first inverted into topside down position and rinsed using a
burst air from nozzle and then are oriented into topside up position, using the guide
mechanism. This saves crucial processing time and increases productivity.
The second innovation is the very low space requirements of the machine due
to a compact structure. The above motor is set in clockwise direction while the lower
motor is set in anti-clockwise direction to speed up the process.

CHAPTER 4: MATERIAL ANALYSIS
4.1 Analysis of types of plastics
4.2 Analysis of types of steels

4.1 ANALYSIS OF TYPES OF PLASTICS
Table 4.1
TENSILE
STRENGTH
LIMITATIONS ADVANTAGES
DELRIN 2400 N/mm² 1. Low coefficient of
friction
1.Excellent machinability
2. High strength and
stiffness properties
3.Good wear and abrasion
properties
NYLON 90 - 185 N/mm² 1. Easily loses its
shape
2. Shrinks easily
1.Used in textiles, fishing
line and carpets
2.High elongation
TPE 2000-4000
N/mm²
1. Highly Costly
2. Tendency to Creep
1.Flexibility and resistance
to compression

Figure 4.1 Courtesy of: plastics.dupont.com

Figure 4.2 Courtesy of: www.dumptruckliners.com
UHMW is chosen over other plastics due to its following characteristics:
1. Highest abrasion resistance of any polymer
2. Outstanding impact strength
3. Intricate parts
4. Cost efficient
5. Improved performance
6. Self-lubricating material
7. Light weight
8. Low Tooling costs
9. Non-Toxic
10. Sound dampening properties
11. Good chemical resistance

4.2 ANALYSIS OF TYPES OF STEELS
Comparison between Mild Steel & Stainless Steel:
Table 4.2
COMPOSITIO
N
LIMITATION
S
ADVANTAGES
MILD STEEL 0.05%-0.25%
Carbon
0.4% Manganese
Tendency to
Rust and
Corrosion
Not that strong
for its Weight
Readily Available
Weldable
STAINLESS
STEEL
0.15% Carbon
16%+ Chromium
3% Nickel
1% Molybdenum
More difficult to
weld
Needs Special
Handling and
WorkSpace
Corrosion Resistant
Durability and Longevity
Better Aesthetic Looks
Significant Strength-to-
Weight advantage
Recyclable
Easily cleaning/Sterilisation
SS-304 is the most optimum quality of stainless steel. Its chemical composition is as follows:
Figure 4.3 Courtesy of: http://www.conexstainless.com/

CHAPTER 5: EPITOME OF AUTOMATED UNSCRAMBLER
5.1 Implementation
5.2 Limitation& Risk Factors
5.3 Project Features & Expected Outcome
5.4 Benchmarking
5.5 Future Scope

5.1 Implementation
The turn table has already been manufactured with high precision and optimum designing.
The turn table consists of 24 bottle stations, which are distributed for different phases of the
bottle unscrambling process.
The motor and gear box have been mounted at the bottom as required and are working
successfully.
The chute that transfers bottles from hopper to turn table has been manufactured. Following
are the snapshots of the manufactured components.
Fig 5.1 Fig 5.2
Fig 5.3

5.2 LIMITATION & RISK FACTORS
This is a machine specifically designed for a bottle with diameter 33 mm and
height 75 mm. Any change in these dimensions will also lead to a change in assembly
and design of machine, which is unsuitable & uneconomical.

5.3 PROJECT FEATURES & EXPECTED OUTCOME
• The PLC controlled rotary disc and support plate will mechanically control the
orientation and processing of bottles as they transition onto a moving conveyor.
• Bottle Unscrambling speed upto 300 bpm, integrated with the function of air rinsing.
• The VFD regulates the motor speed which can vary the output from 100bpm to
500bpm.
• The rotary bottle unscrambler will be a veryuser friendly product.
• Rotary Bottler Unscrambler is economical compared to other types.
• A durable machine.
• Possesses multiple functions in a single machine.
• It will Provide Large number of unscrambled containers with no interruption.

5.4 BENCHMARKING
• As mentioned in the types of bottle unscramblers, rotary unscramble is the least
complicated and most economical machine as compared to the linear, gravity and
visual based unscramblers.
• The bottle unscramblers used in large beverage companies like Coca Cola use
machines that are very huge in size that require more floor space, but the rotary
unscrambling machine I have designed has minimum floor space requirements.
• Minimum material has been wasted while manufacturing UHMWPE plates which
reduces overall cost as compared to other machines.

5.5 FUTURE SCOPE
As discussed in the Market Survey segment, this automatic unscrambling machine has
wide number of functions including bottle orienting and air rinsing.
• Our Machine will be designed for around 120-150 bpm.
• The Machine can be upgraded with faster motor with better rpm to obtain
higher outputs of 400bpm.
• The machine can be upgraded with faster motion & lower gear ratios to obtain
better outputs.
• Such a user friendly and productive machine is definitely a ‘Product in
Demand’ in the market and can be commercialized.
• PLC automation and digitization for more user-friendliness and smoother
operation.
• Use of clutches to reduce accident risks.
• Adjustable and flexible parts/mechanism for different bottle sizes.

APPENDIX 1: PERIODIC PROGRESS REPORT
PPR1

PPR2

PPR3

PPR4

APPENDIX 2: BUSINESS MODEL CANVAS REPORT
Key partners:
• JP Machines & Tools
• Stainless Steel Industries
• UHMW Poly Ethylene suppliers
Key activities:
• Bottleneck Removal
• Problem identification
• Data collection
• Ease of Operations
Key resources:
• External guides
• Design Engineers
• Patent papers

Value proposition:
• Bottle Unscrambling
• Air Rinsing
• Automation of filling process Hygiene
• Minimum Floor requirements
Minimum labour requirements
Customer relationships:
• Healthy business relationship
• Long lasting trustable dealing
Channels:
• JP Machines and tools
• Websites & catalogues
Customer segments:
• Packaging Industries
• Food industries
• Chemical industries
• Pharmaceutical industries
• Beverage industries
• Food-agro industries
Cost structure:
• Material costs
• Fabrication costs
• Manufacturing costs
• Hiring costs

APPENDIX 3: PATENT DRAFTING EXERCISE
PDE 1

PDE 2

PDE 3

REFERENCES
1. Andrea Mandel (26th
April 2010) ‘Bottles – Plastic’
2. HU Rui-hua, MAO Li-min (2011) ‘Dynamic Performance Analysis of Conveyor
Chains under Variable Loading Environment’
3. SutariyaVijaybhaiBabubhai (December 2014) ‘Design and modelling of unscrambler
for bottle packaging’
4. Vasudevan, Karthik (2009) ‘Simulation of High Speed Bottle Manufacturing Lines:
Software Evaluation, Techniques and Results’
5. Wang Liangju, Yang Li,ZhangTiezhong (March 2012) ‘Research Progress of
Unscrambler and its Application on Settling Culture Bottles Automatically’
6. XIANG XINCAI; XIANG XIONGWU (2014) ‘Linear bottle unscrambler of bottle
unscrambling box’

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