boone Posted February 18, 2008 Share Posted February 18, 2008 :grin: Tomorrw (February 19,2008) we will run for the first time our new "J" line. Very high tech, very fast, ground breaking, top of the line, new technology :grin: :grin: It will be a very stressful day to say the least. Two lines of employee's will be trained by machine manufacturer representatives and technicians on how to operate each piece of machinery. A rotating door of employee's will follow in the months to come, until all operators have been trained. I have taken many of you "on tour" countless times. HH hosted SB.com several years ago. They opened the new Bourbon Heritage Center for a special night time tasting. The bottlinghouse tour was included in that event :grin: :grin: :grin: Anyway, back to subject at hand :grin: :grin: I will break these pictures into many post because it's too hard to follow all jumbled into one. Picture #1 Entrance door to the new J-line...O-line is to the right located near the rear of the bottlinghouse. Picture #2 Closer view...just trying to give a little reference (very hard) as to the size of this new line...One line at HH is nearly the same distance as J-line's packer/kicker alone! Just massive stuff. The bottle sorter/orienter is so big I think I could park a car inside... Picture #3...standing just inside the entrance doors. This new line will run plastic (pet) 200, 375 and 750... Link to comment Share on other sites More sharing options...
mozilla Posted February 18, 2008 Share Posted February 18, 2008 BettyeJo,How many people does it take to opperate this unit? :bigeyes: I think that is y'alls 11th bottle line...is that correct? Wasn't that some of the area for the small batch bottle line, used for J....or was that warehouse space previously?Lastly, will this make life easier or harder at the line? Thanks for the insider view. :grin: Link to comment Share on other sites More sharing options...
boone Posted February 18, 2008 Author Share Posted February 18, 2008 Robotics are in firm control at HH. The entire de-palletizer department is operated completely by robot's. The new J-line has a robot all to itself, located right behind the maintenance shop :grin: :grin: At the opposite end of the bottlinghouse. Picture #1 The yellow arm of the robot (upper top left) will swing from side to side to pick up layer's from a pallet of empty bottle cases. Electronic eyes will allow the cases to flow, a row at at time, like ducks in a row :grin: :grin: to the orange rail, then to the blue rail, turn, then upward spiral to overhead conveyors that will carry the cases (over shipping) to the new J-line. Picture #2 They will flow into the first piece of machinery called a "de-caser". The bottles are upright in the boxes. They will flow in (top-left) travel right, turned upside down to release all the bottles. Some bottles inside the cases become very stubborn from time to time. There is a paddler (not visible) a "shaker" of sorts, which shakes all bottles out of the case. The empty case travels upward to a snaking overhead line to the case packer. The bottles fall out, accumulate and travel to a chute to the sorter/orienter. Link to comment Share on other sites More sharing options...
boone Posted February 18, 2008 Author Share Posted February 18, 2008 BettyeJo,How many people does it take to operate this unit? :bigeyes: I think that is y'alls 11th bottle line...is that correct? Wasn't that some of the area for the small batch bottle line, used for J....or was that warehouse space previously?Lastly, will this make life easier or harder at the line? Thanks for the insider view. :grin:You are correct, J-line is the "11th" line at Heaven Hill. This new line was a complete "new addition space" added to Heaven Hill, located behind 0-line, in a section that was a parking lot between the tank farm and the loading docks where the trucker's load :grin: :grin: That will only make sense unless you've visited me in the past :grin: :grin: To all other's, :grin: :grin: in the back of the building :grin: :grin: It takes four less people to run this new line.The way I see it, we've been on overtime for so long I don't know what a regular 8 hour schedule feels like, it's been years! I see it giving relief, but this has been long overdue for as long as I can remember. I hope that means no more ten hours and Saturdays! :grin: :grin: Link to comment Share on other sites More sharing options...
boone Posted February 18, 2008 Author Share Posted February 18, 2008 After the bottles are dumped from the de-caser they travel thru a chute to a huge holding tub :grin: :grin: Picture #1 the de-caser is on the far lower right (grey). Note the empty cases traveling "up" to the overhead, snaking coveyors. The chute for transfer of bottles to holding tub, stainless steel, front and center :grin: Picture #2 It sure holds alot of bottles :grin: :grin: So big you could jump in there and swim around :grin: Note the sorter/orienter thru the lighted glass windows on the machine in the middle. Picture #3 This is the backside of the sorter. It will take each bottle and make them stand, one at at time, open end up, just like a hopper for caps cept this one does bottles :grin: You can see a line exiting this machine, this line will travel to the "cleaner". Link to comment Share on other sites More sharing options...
boone Posted February 18, 2008 Author Share Posted February 18, 2008 Picture #6 This is called the Cleaner. Yes, it cleans the bottles before filling with product. This piece of equipment is worht it's weight it gold! :grin: :grin: This is the 5th one we've installed. It works like a charm, maintenance is easy, quick and the change over is even faster :grin: :grin: Picture #2 Hopper (white) for the capper. This will "up right" the caps for entry to the capper chute. Link to comment Share on other sites More sharing options...
boone Posted February 18, 2008 Author Share Posted February 18, 2008 Fogg Filler/Capper... All these pictures are of the Fogg filler/capper. Distilleries didn't use this brand much. This kind of machine was used mostly for bottling milk and juice products. I've been told that Constellation/Barton's was the first to use this brand of machine for alcohol in their Owensboro bottling facility. Our supervisor used to work at that Owensboro plant as maintenance. He said it's the best! Picture #1 Line leading from the cleaner to the filler. There are little spray nozel jets, located inside that machine for automatic cleaning. The top of the machine is stationary. The bottom carousel moves the plates (holding the bottles) to the stem (54 fo them--red/white). All other fillers, the top carousel moves the stem downward into the bottle neck. Picture #2 The back side. The amazing part with this machine is that the capper is located inside/along side the filler. The exit star wheel of the filler is located nearly side by side with the infeed star of the capper. There are 18 chucks (gizmo that screws the caps on :grin: ) in there. Picture #3 The entry. This is where they hook the hoses up to the filler for product. Picture #4 The exit of the filler. Control panels for Filler/sorter/capper/jog/program etc...etc... Link to comment Share on other sites More sharing options...
boone Posted February 18, 2008 Author Share Posted February 18, 2008 Label machine... PE Executive, is the brand of choice. We started to change the lines to this style machine over 12 years ago. Each installment they get better and better. Picture #1 gives a good view to the "modular" style. This new high tech machine parts are very mobile. We can switch from PS to white glue in a few minutes. You can see the wheels on the mobile station (middle) in this picture. Picture #2&3 are side view and front. Link to comment Share on other sites More sharing options...
boone Posted February 18, 2008 Author Share Posted February 18, 2008 CI-Vision... This machine takes the place of line inspectors There would be two people (inspectors) sitting on this line watching bottles for label imperfectons. I suspect that "if" this machine does a good job they will sweep across all the lines. Many folks will be rolled off the line, to WLD. Link to comment Share on other sites More sharing options...
boone Posted February 18, 2008 Author Share Posted February 18, 2008 Packer-a machine that puts finished bottles into the case... Picture #1 This is the longest piece of machinery (Standard Knapp) at Heaven Hill. It has to be, because it runs so fast that you need a very big accumulation of bottles so you won't run it dry. Picture #2 you can see the snaking overhead lines for accumulation of case in this picture. You can see how far this packer (on left) accumulates with bottles nearly to the label machine! Picture #3 This is the smallest piece of equipment on J-line. It weighs each case after it's been packed. If the weight is not right, it has a big push paddle that will move it off the conveyor to a "dead line". Link to comment Share on other sites More sharing options...
boone Posted February 18, 2008 Author Share Posted February 18, 2008 Sealer/outbound spiral... Picture #1 This machine cuts the side flaps on each case. Note the cases on to the right, the flaps are connected. Note the case on the left they are not. The sealer cuts the flaps, turns the case, pushes the front and back flaps down, drops glue on the top of the front and back flaps, folds the side flaps down so they can seal and then a really good press :grin: :grin: We use taping machines on all the lines except this one and O-line. Picture #2 They eject from the sealer to the outbond spiral that will take the cases ""up" to the overhead line to the palletizer located right beside the robot that loads the line. Link to comment Share on other sites More sharing options...
boone Posted February 18, 2008 Author Share Posted February 18, 2008 Last but not least... Finally... those cases travel from the upward spiral nearly side by side with the incoming case overhead conveyors...they travel over shipping to the palletizer located right beside the robot. Picture #1 A palletizer takes each case pushing turning, counting, raking to line things up and when a layer is positioned just right, and the number is right for that layer, the doors open beneath it...really quick!!!!!!!!! Those cases drop to a wooden skid. that's held up with a hydraulic arm, like you see in car garages when you have tires changed. The lift drops exactly one case deep and the doors above it shut. Starting the process over and over till it's stacked to the desired amount (some take 6 layers, some 5 layers etc.) All of this is controlled with electronic eyes and a PLC. I hope that's not too confusing. It's quite amazing to watch a palletizer in action. Picture #2 When the pallet is full it will completely drop to the bottom and eject to the end of the line (in picture) There is a swivel plate (not visible) at that 45...which in turn delivers it to the wrapper. Picture #3 The wrapper with wrap each pallet with plastic and eject it exactly where that full pallet is now (in picture). A fork truck will pick it up and deliver it to the full case warehouse. Link to comment Share on other sites More sharing options...
cowdery Posted February 19, 2008 Share Posted February 19, 2008 Very pretty, very impressive. Good for HH. Thanks for the tour. Link to comment Share on other sites More sharing options...
melting Posted February 20, 2008 Share Posted February 20, 2008 Is this your first piece of Lantech equipment? We have three Lantech stretch wrappers at the shop. One is about 15 years old, the second is about 8 years old and we just received the third one about 6 months ago. They are pretty durable mechanically, but we've started experiencing electrical problems with the two newer ones lately.I'm not positive but I think Lantech is middle of the road when it comes to palletizing equipment.Chris Link to comment Share on other sites More sharing options...
boone Posted February 28, 2008 Author Share Posted February 28, 2008 Very pretty, very impressive. Good for HH. Thanks for the tour.Monday, they held the official ribbon cutting ceremony. Max gave a small speech...cut the ribbon...took a small tour and then a few refreshments.For those not familiar with HH folks the last three people (far right) Max Shapira cutting the ribbon, his son in law Alan Latts (married to Kate-- Max's daughter) and Andy his son.Kentucky Standard Online.pdf Link to comment Share on other sites More sharing options...
mozilla Posted May 5, 2008 Share Posted May 5, 2008 Bettye Jo,I am sure you have told us this before....when was your bottle house built? I saw a pic in a book where it was not there, though it was a very old photo. Was there a bottle house next to the old stills? Did they move any of the equipment from after the fire, to your building?Thanks! Link to comment Share on other sites More sharing options...
boone Posted May 5, 2008 Author Share Posted May 5, 2008 The "present" bottling house was built in 1964. Before that, the bottling lines were down below the hill (DSP # 31) at the distillery. There is only one piece of equipment from the old bottling-line still operable today (:bigeyes: ) That piece is the case sealer on A-line (200 ml)...the first line you see when you enter the bottling house.Bettye Jo,I am sure you have told us this before....when was your bottle house built? I saw a pic in a book where it was not there, though it was a very old photo. Was there a bottle house next to the old stills? Did they move any of the equipment from after the fire, to your building?Thanks! Link to comment Share on other sites More sharing options...
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