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Filler relies on networked PCs

At Catania-Spagna, a 12-head rotary liquid filler controlled by PCs linked via Arcnet and Ethernet communications protocols allows real-time data acquisition and analysis.

Phil Arnone (left), maintenance manager at Catania-Spagna, demonstrates how easy it is to gain access to the filler's on-board P
Phil Arnone (left), maintenance manager at Catania-Spagna, demonstrates how easy it is to gain access to the filler's on-board P

According to Charles Sutera, head of sales at Catania-Spagna, steady growth in sales of the firm’s vegetable and olive oils over the past two years brought the company two choices in its approach to packaging: add more shifts or find a faster filler.

Faster filling was the choice made by the Ayer, MA, firm, and the filler selected was a 12-head net-weigh rotary filler from EPSI (Bogart, GA). Its PC controls system allows it to fill 1-gal plastic bottles of edible oils at 85/min, up from 52/min on the old filler. Vice president of operations Steve Sampson calls the filler, purchased through Jaffco Packaging Machinery (Uxbridge, MA), “phenomenal.”

“Everyone we talked to in the field said we’d need at least 18 filling heads to reach the speeds we needed,” says Sampson. “But we didn’t have the room for an 18-head filler, and it would have cost another $100ꯠ.”

Sampson is equally pleased with the machine’s filling accuracies. “Quotes from other machinery builders were in the range of plus or minus five grams per gallon,” he says. “EPSI quoted one to two grams.” In operation since February, the machine has actually exceeded its maker’s claim. “I have the statistical data to prove that on our one-gallon bottles, we’re holding to within five hundreths of a gram,” says Sampson.

The new filler performs as admirably as it does, says Sampson, partly because it’s mechanically solid. But structural reliability is not what makes the filler such a powerful tool. “It’s powerful because of its controls package,” says Sampson.

PCs are linked

That package consists of two PCs connected via the Arcnet communications protocol and a third PC connected over Ethernet. Both Arcnet and Ethernet are open standards not dominated by any one supplier. The PC controller on board the filler, a 486 100-MHz processor, runs Intellution’s (Norwood, MA) Paradym PC-control software on top of the standard DOS operating system. This PC handles all the real-time machine control. Based on machine position, it determines when to signal the solenoids that open and close the filling valves. It monitors the load cell in each station, and with each fill cycle it tares the empty bottle, begins filling, stops filling and makes corrections for the next fill if the previous fill was off target.

The second PC in the network serves as the human-machine interface (HMI) station running Intellution’s Fix HMI software. It is a Pentium II, 400-MHz PC that’s connected to the on-board PC controller via Arcnet.

The operator uses the HMI to choose filling parameters from a menu, and this information is transferred to the onboard PC over Arcnet. The onboard PC then controls the filler based on the parameters it receives from the HMI PC.

The controller also sends back to the HMI via Arcnet a wealth of real-time data—how long it took to tare the empty bottles, weight of empty bottles, how long it took to fill, fill weights, etc.

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