Precise format adjustments in labelling machines at 1,000 bottles per minute

• What was needed:  drylin® W-linear guide, drylin® SLW linear unit with spindle drive,  xiros polymer ball bearings, E2/000 series energy chain
• Requirements: High requirements for a throughput of 1,000 bottles per minute: high precision, corrosion resistance, resistance to cleaning agents, high wear resistance, lubricant-free
• Sector: Beverage industry, bottling plants
• Success for the customer: Whether height adjustments, deflection rollers or adjustment of the work table: the rotary and linear bearing technology used has been fulfilling the high requirements in various KHS systems for around twenty years. The customer not only receives the bearing, but also the completely ready-to-install functional components.

60,000 bottles per hour or 1,000 bottles per minute and almost 17 every second: this is the output of a typical KHS beverage filling and packaging line. KHS traditionally sees its core competence in labelling technology and is one of the global market leaders in this field.
KHS offers bottlers labelling stations for various technologies (hot melt, cold glue, roll-fed or self-adhesive). One of the latest developments in the "Innoket Neo" modular system is the roll-fed station, which replaced its predecessor, the Innoket 360S, at the end of 2016. Roll-fed means that the wrap-around labels are unwound from a roll, cut to the correct length in the cutting unit and glued on a roller. They are then applied to the bottle. The bottle rotates during the transfer of the label, which is brushed off directly. Typical of this technology is the "autosplicer", which seamlessly splices the two label rolls and thus ensures uninterrupted operation of the machine.
With a breathtaking speed of around 1,000 bottles per minute, high demands are placed on all moving components, especially their precision.
KHS' strategy: when developing new labelling technology, modules and systems for individual functions - such as horizontal adjustment or deflection rollers - are increasingly being purchased as ready-to-install components. A whole series of requirements must be met. Moisture and humidity during filling require components that are highly resistant to corrosion and common cleaning media. High wear resistance and hygiene are at least as important. lubrication-free components help to avoid contamination - especially when labelling empty, open bottles.

The bearing technology used - rotary iglidur® bearing bushes as well as drylin® linear technology - has been fulfilling the high requirements in various KHS systems for around twenty years. What is new, however, is that the customer not only purchases the bearings, but also completely ready-to-install functional components. Numerous examples of this can be seen in the Innoket Neo roll-fed station:

Height adjustment of the cutting mark sensor
For example, the height adjustment of the cutting mark sensor**(see image 1 below**). Until now, KHS has always assembled this function itself from numerous parts. Now they are completely supplied by us: with linear adjustment option, clamping, scale tape measure and fastening for mounting. The basis is a drylin® W-linear guide type WS-10-40.

Return rollers of the label guide
A second example are the deflection rollers for the label guide through the roll-fed station**(Fig. 2**). The rollers - which are of course also lubrication-free and corrosion-resistant - are fitted with xiros polymer ball bearings (Fig. 3). The roller material was selected in practical tests to ensure exactly the desired frictional resistance.

Adjustment of the worktable
Another complete system is the horizontal adjustment of the entire worktable. This is used to adjust the distance between the roll-fed station and the basic machine. The adjustment is made by hand crank using a drylin® SLW threaded spindle (Fig. 4). The rear guidance was designed with drylin® W-linear guide type WSQ-16**(Fig. 5**). And an energy chain from the E2/000 series is responsible for the flexible supply of energy, signals, vacuum and compressed air to the labelling station**(Fig. 6**).