Process Pilot® Automated Blowmolder Control System

Automated blowmolder control system for PET container production

The Process Pilot® automated blowmolder control system is a combination of software and hardware interface components that work in conjunction with the Pilot Profiler™ measurement system to provide a hands-free means to maintain the blowmolding process. The Process Pilot control system utilizes feedback from the Pilot Profiler™ system to continually monitor material distribution and automatically adjust blowmolder settings to maintain optimal bottle distribution characteristics, without operator intervention. The Process Pilot system eliminates time-consuming manual steps in the blowmolding management process, resulting in reduced process variability and improved bottle performance and quality.

“The Process Pilot system can control the blowmolder process to a level of precision unmatched by methods that rely on limited feedback from weight-based data.”

The Process Pilot automated blowmolder control system offers more effective management of common blowmolder issues such as:

  • Preform variability
  • Startup transients
  • Environmental changes
  • Operator experience
  • Overall more consistent blowmolder operation
  • Reduced process and environmental variability
  • Improved ability to light weight
  • Improved overall bottle quality and performance
  • Reduced rejects and scrap

Features

  • Easy to use, “set and go” style operation
  • Adjustable process control limits
  • Built-in alarms and controls to protect the blowmolder
  • Simultaneous management of multiple parameters including oven lamps, pressure, preform temperature and timing
  • Compatible with all major brand blowmolders
  • Seamless integration with Agr Pilot Profiler™ distribution monitoring systems and Pilot Vision inspection system

Lighter bottles demand more precise operations, especially in handling…Our research and manufacturing teams huddled and looked for new ideas to overcome line issues. Through trial and error with our new bottle designs, we learned Agr’s process monitoring is the best tool available today that is compatible with all leading blow molding equipment to assure we make the most consistent bottle we can for our downstream process.” – Sid Khanna, manager manufacturing solutions, Niagara Bottling

The results of the automated control system are quantifiable and substantial.  In the 12 months following the installation, the plant experienced a 52.7% improvement in waste reduction.  Looking at all the benefits, including enhanced productivity and the savings in raw material due to consistent output, the payback period for the new system was less than one year. We’ve also seen a big improvement in statistical process control indicators such as Cpks and PPKs since we added the Process Pilot and OptiCheck…Our productivity and customer satifaction have increased, and we don’t run our jar line without them.”  – Don Waud, Plant Manager, Graham Packaging

The Process Pilot provided “reduced process optimization time at start up, improved bottle performances, reduced influence of operators on blowmolder settings and a decrease in rejected packages…With Hurana’s production of millions bottles per month, the savings are considerable…Suntory intends to extend deployment (of Process Pilot) to additional blowmolding lines, bringing it increasingly closer to the light-weighting goals of our sustainability campaign.” – Mr.Kobayashi, Deputy General Manager, Suntory

Agr Customers