• Final product appearance is critical in all industries, but perhaps none more so than the beverage and food industry. Brands compete for discerning customers’ attention in an increasingly competitive market where even the smallest imperfection can be enough to sway the purchasing decision. This is especially true for the major retailers and supermarkets that expect exacting standards in product presentation. Any distortion of labels or sleeves can be the difference between securing that key customer.
• The bottling process is an inherently wet one. Moisture arises from over-filling, pasteurising, cleaning and condensation – but this all needs to be removed prior to final packing. Any liquid present on the bottle before final packing can cause degeneration of packing, labelling, caps and crowns. Failure to present bottles and their surrounding packaging in perfect condition will result in delivery rejection and affect relationships with major retailers and the end customer.
• Any liquid present on the can before final packing can cause packaging degeneration, corrosion, discolouration and blemishes, including corrosion of the tab on the ring pull or hygienic labelling that requires specialist attention. Failure to present cans and their surrounding packaging may mean losing your market position.
• Labels are the most common form of branding applied to bottles; they are the first point of communication to the end customers in the supermarket. But it’s not just what they say that influences a customer’s decision – it’s how they look on the shelf. They represent the brand image, and aspirations, the quality of the product and reputation of the organisation. It is no wonder that poor label appearance is a primary reason why customers don’t pick up a product off the shelf.

• Understanding the cause is the first step towards developing a solution. Slipped, peeling, or misaligned labels on the bottle neck and body are most commonly caused by liquid on the bottle surface prior to label application. Surface moisture creates 4 primary issues:

• Surface water is frequently transferred to the glue pot, resulting in foaming or dilution of the glue. This creates unsightly streaking of the glue beneath the label. The glue may also be diluted during application, reducing the adhesive strength and increasing the time it takes the label to adhere to the bottle. This causes the label to slip out of alignment, especially in mass flow areas and on bottles without a label protection panel.

• Residual moisture leads to misalignment or complete failure of the head on pre-glued label applicators.

• Liquid trapped underneath the label causes bubbling and distortion and can be seen through clear substrate materials.

• The primary cause of poor quality marking is condensation and surface moisture from upstream processes. The water can dilute the inkjet, causing the ink to spread on contact with the surface and resulting in faded, smeared and illegible markings. Rather than pay a premium for expensive ink, it is often more cost-effective and significantly lower risk to thoroughly dry the bottle prior to coding.

• Shrink sleeves are a popular form of packaging due to their attractive nature and flexible application. However, loose fitting or deformed sleeves will seriously affect customer perceptions of a product at the point-of-sale.

• The formation of a sleeve brings plastic substrate into contact with the bottle surface. If liquid is present on the surface the sleeve can prematurely bond to the bottle and cause loose fitting or wrinkled sleeves. The use of steam tunnels also creates residual moisture on the surface of the bottle which must be removed to avoid being transferred into downstream processes. Rejection rates, wastage and down time can be significantly reduced by ensuring that bottles are dry before entering any inspection system.

• The ever increasing processing speeds on pouch filling lines require even more attention to be paid to drying in order to prevent costly stoppages and processing errors.

• Seal integrity inspection is undertaken by passing an ultrasonic signal through a closed seal. If there is a pinhole, crack or leak within the seal the pocket liquid will cause a reflection of the ultrasonic wave and weaken the signal strength - this results in a rejection of the faulty product.

• However, surface moisture around the seal will also cause signal weakening and result in a false positive rejection. Rejection rates, wastage and down time can be significantly reduced by ensuring that pouches are dry before entering any inspection system.

• Dry loose debris left on outer surface of packaging creates bacteria build up and creates a bad impression on concerned buyers.

Solution

• Ring Blower assisted AIR KNIFE SYSTEM can address all of above issues and more.Ring Blower assisted AIR KNIFE SYSTEMS are very efficient, cost effective, energy saving, environment friendly solutions which can be easily integrated with your present day production lines.

• AIR KNIFE SYSTEM is non contact method of removing unwanted surface liquid, moisture, dirt, coatings, contamination, debris, and heat, static charge etc during manufacturing process of predominantly conveyed (moving) articles or parts. AIR KNIFE SYSTEM powered by low pressure air from RING BLOWER devices a continuous LAMINAR SHEET/ STREAM/ CURTAIN of precisely controlled HIGH VELOCITY AIR.

• This SHEET/STREAM/CURTAIN OF HIGH VELOCITY AIR pushes the liquid from the surface of the article/product and residual moisture is shattered from the article/product. This mist is carried away by continuous stream of air. This SHEET/STREAM/CURTAIN OF HIGH VELOCITY AIR also blows away debris, cleans surfaces, dissipates heat, spreads/ dries coatings, takes away static charges, protects surface etc. In certain applications where longer/deeper reach of HIGH VELOCITY AIR is required NOZZLES could also be used.

• Drying with RING BLOWER ASSISTED AIR KNIFE SYSTEMS has been known to CUT COSTS by 80% compared with THERMAL DRYING AND COMPRESSED AIR SYSTEMS.

• An effective working AIR KNIFE SYSTEM can be assembled using standard single or multiple AIR KNIFES, located strategically. For certain applications combination of AIR KNIFES with AIR NOZZLES will bring desired results; System will also incorporate ideally placed Single or Multiple Blowers, Flexible Hoses, Clamps, Manifolds and such accessories.

• AIR KNIFES AND NOZZLES are available in different sizes, lengths and shapes. Most common material of construction is Surface Treated Aluminium Alloy. AIR KNIFE & NOZZLES can also be supplied in 304/316 S.S. Speciality Filters are available to meet most stringent standard for Food, Pharmaceuticals, Electronic or similar applications.