Robo-QCS: An innovative in-line automatic system

Carrying out several non-destructive quality control operations at any one time during production can optimise the production process and prevent non-conformities, which ensures complete product quality. 

Robo-QCS, the automatic robotic system developed by FT System – part of Antares Vision Group – was developed to achieve these objectives. Let’s analyse its full potential in detail.

Non-destructive inspections can be carried out simultaneously in a single analysis platform. Usually, four types of controls or measurements are identified:  

1. Weight and volume control
2. Checking correct cap application by measuring torque and application angle
3. Measuring the concentration of gases in the headspace (e.g., CO2, N2, etc.)
4. Measuring microleaks between cap and preform

How Robo-QCS can do these inspections simultaneously 

A robotic arm picks up samples from the production line and inspects them in an automatic analysis station through non-destructive tests. 

These controls are required by law or necessary to optimise and satisfy internal processes and procedures. Compliant samples are automatically reinserted in line. It is not necessary to change the production speed of the line and no operator intervention is needed.

Line efficiency is improved by Robo-QCS

The inspection and quality control on the samples are performed in real-time in the automatic analysis station next to the production line, and this replaces the manual checks carried out on the line. The data is automatically time-stamped and correlated with the efficiency of the filler and the correct operation of the capper. 

It is therefore possible to recalibrate the upper packaging equipment instantly in the event of deviation from specifications, monitor trends over time and plan targeted and punctual preventive maintenance.

Benefits that can be achieved with Robo-QCS

Controls of the Robo-QCS allow:

• Recalibrating filling valves that do not fill properly – On average, the standard procedure involves a random manual weighing of 20 bottles every four hours. If a deviation occurs to the filling valve during this time, overfilled or underfilled bottles are produced. With Robo-QCS there is a real-time level control preventing large non-compliant productions. The correlation of the sampled bottles to the single specific filling valve provides additional important information enabling additional controls and dedicated adjustment. This is extremely important information that, with manual sampling, is difficult to have. 
• Evaluating the correct application of the cap – The standard manual procedure involves checking the torque on a random sampling of 20 bottles every 4 hours. With Robo-QCS, continuous checks for the correct application of the cap through removal torque and application angle. Automation allows specific monitoring of the individual capping heads without the need for operator intervention and eliminating the randomness of sampling, as per the filling valves. 
• Checking the filler and the capper at the same time with immediate possibility of maintenance – With Robo-QCS it is possible to control two or more parameters at once. This means being able to set the equipment very close to the correct setpoint, allowing to plan interventions and maintenance 
• Reducing the production loss – The checks carried out with Robo-QCS are all non-destructive and therefore the samples used for the inspections can be placed back into the packaging line and to the market 
• Digitalising the data – Robo-QCS produces date and time reports that can be shared digitally and used retrospectively during an audit, to optimise internal processes or recover data from a specific batch.
  
• No variability due to operator when making measurements – With Robo-QCS no operator is needed on the line; inspections and records take place automatically, thus eliminating the possible influences of manual verification.

Integration with smart data management software 

All the data of Robo-QCS can be uploaded by Avionics, a solution to monitor and manage data to maximise quality, performance, and maintenance of the bottling line. Avionics can collect and/or upload data from inline and offline machines or instruments, analyse and correlate them to facilitate making decision process about:

• Raw material correlated to the supplier in order of production line
• Digitalise all data of production line to elaborate analysis and report in real-time
• Evaluate performance and quality of different production lines, but also of different facilities to a corporate level
• Toward data analysis can reduce the cost and maximise the yield

Avionics facilitates the root cause analysis and is supported by AI (artificial intelligence) and ML (machine learning) engines to implement preventive and predictive activities.