A new automated material distribution measurement and process control system is providing blow moulders with a cost-effective, entry-level way of ensuring that all production bottles have the required quality and performance attributes.
Geared towards lines producing PET bottles with less complex geometries at lower speeds, the Pilot Core system from Agr International is pitched as a prime solution for 24/7 process control.
The system mounts inside the blow moulder and automatically controls the production process based on continuous monitoring of material distribution on every bottle. According to Agr, the comprehensive and precise thickness measurement provided by the Pilot Core system is key to accomplishing proper process control – without operator intervention.
The automated system monitors operation 100 per cent of the time for the slightest changes in material distribution and continuously adjusts the blow moulder to keep the process on track. This is a level of control that is unattainable by human operators.
Material thickness is no hinderance
The system has 12 evenly spaced points that provide direct measurements over the sidewall of the bottle, regardless of shape or material thickness. Any change in distribution can be identified from source to destination.
With this type of feedback, Agr says the Pilot Core system provides precise process control and monitors performance factors on a per bottle basis while eliminating the variation in environment, material or operator experience.
This comprehensive measurement approach offers a complete understanding of the bottle – and through continuous monitoring and adjustment – maintains the blowing process at optimum levels.
Agr claims the optimisation keeps the process efficient and cost-effective, providing real savings in:
Materials
Productivity
Quality
Reduced scrap
Overall cost
Energy
Downtime
Labour
Consistent quality is critical
The Pilot Core system is designed for high-volume PET bottle production in the beverage industry, where consistent quality, efficiency and material optimisation are critical. It automatically adjusts the blow moulding process in real time, helping maintain stable output despite variations in materials, machine operators, or environment.
The system improves production efficiency by reducing scrap, resin usage, energy consumption, and downtime. It lowers reliance on manual adjustments, resulting in more stable and predictable line performance.
It also enables lightweight bottle designs and higher rPET usage to support sustainability goals without compromising quality.
With its ability to maintain consistent process control in demanding production environments, the Pilot Core system helps ensure reliable output, improved efficiency, and optimises resource usage across the entire blowing process.
More information from Agr International
