Skip to main content
Success Story | 2 minute read

Optimizing Bottle Production

Kollmorgen Solution Catapults PET Bottle Blow Molding Machine to Top Producer in the World

Challenge

A major bottling operation in China needed to substantially increase output in order to ensure future success in a highly competitive market. For the company’s all-electric linear PET bottle blow molding machine, productivity depends on the ability to quickly index PET preforms into position and then remove the resulting molded bottles. The company engaged Kollmorgen motion experts in early 2019 to help minimize the machine’s indexing time.

Working closely with the customer’s machine design team, Kollmorgen engineers discovered that the indexing performance requirements were overtaxing the existing motor/drive solution. The motor wasn’t able to achieve the desired indexing speed without overheating. The drive was unable to supply the necessary acceleration current and would quickly go into current foldback, further limiting the power needed to meet the desired indexing time.

The only way to prevent overheating and foldback in the existing motor/drive combination was to increase the indexing time – slowing the machine down to the point that bottle-production targets could not be met. While a larger motor might have solved the problem, the machine design was fixed and did not provide the additional space that would be needed.

Solution

Achieving faster indexing times would require more acceleration torque and lower overall inertia. Kollmorgen worked closely with the customer to evaluate the indexing goals and to co-engineer a solution that would deliver the desired machine performance improvements. A Kollmorgen 2G Motion System supplied the additional power needed to dramatically decrease index time while occupying the same space as the prior motor and drive design.

Results

A simple, cost-effective upgrade to the 2G Motion System transformed the PET bottle blow molding machine and reinvigorated the customer’s business.

  • Motor torque increased by 30% without an increase in size.
  • Faster acceleration reduced the indexing time from 1.6 seconds to 1.3 seconds, a 23% improvement.
  • No machine modifications were required to fit the AKM2G servo motor onto the existing motor mount, saving the customer design and documentation time.
  • The machine now produces 156,000 bottles (600 ml) per hour, making it the #1 bottle producer in the world.

“This is what the 2G product was designed for —increasing the performance of our customer’s machine without taking away precious space for a larger drive and motor.” - Tom Kunkel, 2G Product Manager, Kollmorgen

Learn more

Ready to discover what the 2G Motion System can do for your machine?

Learn more

 

About Kollmorgen

Since its founding in 1916, Kollmorgen’s innovative solutions have brought big ideas to life, kept the world safer, and improved peoples’ lives. Today, its world-class knowledge of motion systems and components, automated guided vehicle navigation software, industry-leading quality, and deep expertise in linking and integrating standard and custom products continually delivers breakthrough motion solutions that are unmatched in performance, reliability, and ease of use. This gives machine builders around the world an irrefutable marketplace advantage and provides their customers with ultimate peace of mind.

Advanced Surgical Robots: Designing Compact, Powerful Motion for the Next Generation

Learn the key criteria for designing axially compact arm joints that minimize space, maximize torque, and deliver precision performance in surgical robots.
Learn More

Monitoring and controlling brakes through on-drive functional safety technology

How can you ensure the safety of vertical loads while complying with ISO 13849-1? On-drive safety functions offer a no-compromise way to simplify brake testing.

Learn More

Engineer the Exceptional

Learn how to engineer exceptional machines, robots and vehicles with the highest-performing, most reliable motors, drives, automation solutions and more.

Learn More

Related Resources

Ground satellite 

AKD2G 24A Data Sheet >

Kollmorgen’s new AKD2G 24A servo drive delivers 3x the continuous current capacity and offers a rich feature set for simple integration in complex applications. 
Kollmorgen Express Delivery significantly shortens lead times for the company’s most popular motion products

Kollmorgen Express Delivery significantly shortens lead times for the company’s most popular motion products >

Motion leader Kollmorgen announces a new classification for select products that can be delivered within an accelerated timeframe.
Surgical robotic arms in operating room.

Advanced Surgical Robots: Designing Compact, Powerful Motion for the Next Generation >

Learn the key criteria for designing axially compact arm joints that minimize space, maximize torque, and deliver precision performance in surgical robots.
Kollmorgen White Paper, Monitoring and controlling brakes through on-drive functional safety technology

Monitoring and controlling brakes through on-drive functional safety technology >

How can you ensure the safety of vertical loads while complying with ISO 13849-1? On-drive safety functions offer a no-compromise way to simplify brake testing.

Stop, hold and go safely: Motion tuning for vertical loads >

When designing motion for applications such as vertical gantries and hoists, you need to take special care to ensure operator safety and operational efficiency. Let’s discuss best practices for meeting the particular challenges involved.

5 Key Reasons to Consider an Upgrade to AKD2G Servo Drives >

Advances in processor technology for servo drives continue to expand the features and capabilities they offer. Choosing a new drive or control system over an existing system ultimately depends on the application requirements. The AKD2G servo drive…

What are the Five Major Components of a Brushless Servo Motor >

Servo motors are used in numerous markets to power machines, instruments, robots, and other factory automation applications. This blog addresses five major elements of a conventional brushless DC servo motor: the rotor, stator, bearings, feedback and…
What is a closed-loop system?

What is a Closed-Loop System? >

When learning about servo motors and servo systems, you’re likely to encounter the phrase “closed-loop system.” If you’ve ever wondered what that means and how it works, you’ve come to the right place. Let’s step through some of the most common…
Printing Machine

Direct Drive Motors Improve Flexographic Printing Performance >

Recent work done by Kollmorgen—a global leader in manufacturing motor and motion solutions—has shown that it is possible to synchronize components within the flexo printing process without mechanical transmission by using closed loop control…