Peterstaler Mineralquellen has invested in a new filling line for glass bottles. A breast label with a security seal flap is used for the first-opening guarantee prescribed in Germany. The innovative adhesive application technology from Robatech is used in the KHS Innoket Neo labeller.
Bad Peterstal in the Black Forest is particularly well known for its mineral springs, which were discovered in the first half of the 19th century. Peterstaler Mineralquellen GmbH was officially founded in 1926 and expanded in 1941 to include a second production site in nearby Bad Rippoldsau. In addition to mineral water, the company also produces lemonades, spritzers and sports drinks and is still family-owned today. The drinks are bottled in Glass or PET bottles in different sizes and as Disposable or reusable containers. In total, there are currently around 80 different products in the Peterstaler Mineralquellen range.
Mineral water back in glass bottles
The mandatory deposit on disposable packaging introduced in Germany on 1 January 2003 initially caused the market for disposable glass bottles to collapse for several years. In the last three to four years, however, mineral water in glass bottles has experienced something of a renaissance. The general trend towards healthy eating and regional products has given glass a new lease of life as a beverage packaging. Classic mineral water brands have been recording stable growth in this product segment again for several years. At the beginning of 2015, the management of Peterstaler Mineralquellen therefore took the far-reaching decision to introduce a New glass filling line which was to be installed at the Bad Peterstal site. At the same time, the company also invested in a New logistics centre invested.
New glass line from a single source
A completely new glass bottling line was also planned, as the existing equipment at the Bad Rippoldsau site was already noticeably outdated. Various machine manufacturers were therefore evaluated and in the end Peterstaler Mineralquellen opted for KHS as a full-service provider who could supply the entire system, including conveyor belts and labellers, from a single source.
„We wanted another system with the Capacity of 30,000 bottles per hour acquire. The system was to consume significantly less energy, be operable by two people and be able to be installed in our confined space of 600 metres.2 can be installed on the first floor. Very important for us were Short set-up times, on average, the system is converted to a different format every three to four days,“ says Technical Manager Wolfgang Sum, summarising the requirements.
Peterstaler Mineralquellen decided in favour of a system from KHS GmbH, based in Dortmund. As the labeller, KHS installed its Modular Innoket Neo system. Machines from this series can apply self-adhesive, cold glue, roll-fed and hot melt labels at an output of up to 60,000 bottles per hour. Five different glass containers are labelled on the Bad Peterstal machine: 0.5-litre and 0.7-litre GdB bottles as well as 0.25-litre, 0.5-litre and 0.75-litre catering bottles.
According to the German Mineral Water Ordinance, mineral waters may only be labelled with a Originality guarantee be placed on the market. This can be done using a screw cap with a tamper-evident ring or by sealing with a label.
Secure hold of the sealing label
Peterstaler Mineralquellen has always used a Label sealing and wanted to stick with this solution. The chest label has an upward-facing flap that is applied to the screw cap using a hotmelt adhesive dot. When the bottle is opened, the paper label tears between the cap and the breast of the bottle and the opening becomes visible. To apply the Hotmelts KHS relies on the technology of Robatech AG, based in Muri.
A Robatech Concept B5/2 melting system melts the hot melt, which is conveyed to the SpeedStar Diamond application head via a waterproof heated hose. For use a single order header. „With the SpeedStar, two hot melt dots are now applied to the lid in the KHS rotary labeller. As the aluminium screw caps also have a thread on the outside, there would be a risk of the hot melt being accidentally applied to a thread valley if there was only one dot. Two dots of glue ensure that at least one thread crest is hit, which is necessary for a secure hold of the sealing label,“ says Andreas Felder, Sales Manager Southwest at the German Robatech branch in Bad Camberg. In addition, the glue dots are sealed with a Infrared sensor checked for their presence. Bottles with unaffixed sealing labels are rejected. „Order control is performed by the Robatech AS 50 AK controller, which is connected to the KHS system controller via Ethernet. This allows the customer to control our order control system via the KHS touchscreen.“
Spray gluing technology as the first choice
Wolfgang Sum is very satisfied with Robatech's adhesive application system: „I was already familiar with Robatech's spray gluing technology from before and was keen to have another system like this in our new glass filling line. We were therefore delighted that KHS had already suggested a Robatech adhesive application system as standard in the Innoket Neo.“ KHS mainly integrates systems from Robatech into its lines. „Our control panel corresponds well with Robatech solutions and the signal exchange works perfectly. Unless the customer requests otherwise, Robatech's adhesive application systems are our first choice,“ says Cornelius Adolf, Product Manager for Labelling Technology at KHS. The company's systems can also be easily retrofitted to existing lines.
„Since we only bottle on one glass line, the Permanent availability particularly important for us,“ says Wolfgang Sum. „The perfect quality of the adhesive application technology offers us a High security in production. In addition, contact with Robatech's service technicians is competent and direct. If a small problem arises, it is solved immediately. We are also satisfied with the Sustainability of the system, as both energy and adhesive consumption have been reduced.“ The new glass filling line was inaugurated in February 2016 and has been running smoothly ever since.
[infotext icon]The Robatech Group, headquartered in Muri, Switzerland, is a leading global provider of adhesive application systems for a wide range of industries. The product range of the service and technology leader for green adhesive application solutions includes hot melt, cold glue and PUR solutions. Robatech is represented in over 60 countries and has been supplying high-quality controllers, application heads and dosing systems that are exemplary in terms of speed, precision and reliability since 1975.
