How can 5 gallon bottle water factories increase production efficiency?
To ensure a successful bottled water production, you need to put more emphasis on efficiency and output in addition to maintaining the highest standards of hygiene and safety.
No matter how large or small your manufacturing plant is, efficiency and productivity relative to your capital investment are the keys to maintaining your competitive edge. The first step in optimizing your production efficiency is to measure your plant's current productivity level. You can then take actions to improve and measure their effects after this step is complete.
Process efficiency metrics
In order to evaluate the efficiency of this process cycle, a metric must be used. Some popular metrics are:
- Value-added time (the time spent creating your product(.
- Resource efficiency
- Labor productivity
- Throughput (i.e., the output of a process or machine for a unit of time)
- Quality (i.e., the number of outputs that are acceptable for use or free of defects)
Measuring just one metric will not give you an accurate picture of productivity, and it can even be harmful.
Taking multiple factors into account, such as Value-added time, labor productivity, and Quality at the same time will help you to pin down what your plant's productivity looks like.
IMPROVE EFFICIENCY OPPORTUNITIES
At every stage of the production process, there are opportunities to improve efficiency. Take a look at these steps and efficiency options for water bottling:
Step one: Delabeling & Decapping
Removing caps and cutting the sleeve film by hand is increase Labor costs and Value-added time and could be a bottleneck in the production line. Fortunately, there is a range of manual to automatic options for removing caps that you can choose based on your production capacity. The removing caps and seal film is processed by professional equipment such as BY-BG-series, BY-DLDC-series, BY-DL- series to effectively prevent the traditional manual cleaning with blades, which makes scratches at the neck of the barrel. In the long run, small wounds of the neck of the barrel become larger, leading to lax sealing, excessive growth, and unqualified sampling in the market, which leads to punishment by the market regulatory office or you will need to replace the bottle with a new one very soon.
Step 2: cleaning and washing bottles
The first point about washing bottles is that the washing place should be completely separate from the bottle filling place to reduce the risk of pollution and contamination of the product. There are machines on the market for washing and filling bottles at the same time, but in this type of machine, the risk of contamination of the final product is very high.
Another suggestion to improve the efficiency of the washing system is to use two independent machines for washing inside and outside the bottle, which in addition to improving performance, leads to more flexibility of the production line.
Brushing is the most common method for cleaning the outside surface of the bottle. The barrel is entered from one side, and the barrel body is clean and tidy after rotating scrubbing with a brush.
For washing inside of bottle high-pressure water washing and particle friction washing technology are the most efficient technology that already is available in the market
In high-pressure water disinfection pretreatment, High-pressure water (up to 80 bar pressure) with 360 degree rotation spray in the bottle, to ensure that there is no dead Angle of the barrel body internal disinfection.
In particle friction technology, usage particle friction for washing in combination with simultaneous rotation of barrels in two axes including rotating the barrel in line with the main axis of the machine (main drum) as well as rotating the barrel around its axis, provides full access to all corners of the barrel for washing machine. Read more about particle friction technology.
Due to lack of access to barrel corners, the brush washing machine has not a good performance for inside bottle washing and is not recommended.
Read more about How to choose a bottle Washing Machine to help you find the best washing machine for your factory.
Step 3: fine washing and sterilization, filling and sealing
It’s recommended to merge the final stage of washing, filling, and capping in one machine to guarantee the highest level of bottle hygienic quality and to avoid contact between the labor hands, valve, etc., and the neck of the bottle (risk of contamination transfer). Ultra-clean monoblock (3 in 1) machines such as BY-XGF-series could be the best option to satisfy the strictest hygienic demands with minimum operator and labor cost.
Step 4: warehousing
The last step of production is external packaging and warehousing which also could be a bottleneck of your production system so you need to choose suitable machines for bagging, product date coding, palletizing as per your capacity, factory space, labor cost, and your distribution channels. You can find more detail about palletizers in “Which palletizer system will be best for you?”
You can also ensure very high production efficiency when you purchase your bottled water production machine from manufacturers with a good reputation for quality. This will be of great help to your time, energy, and money-saving efforts.