150 PCS/Min! MDSC-2100L Helps Cap Enterprises Solve High-Speed Pad Insertion Detection Challenges

1. Case Background

With the consumption upgrade in the beverage and daily chemical industries, bottle caps, as key components of product packaging, face higher market demands for production efficiency and quality stability. A leading bottle cap manufacturing enterprise, aiming to gain market share, launched a capacity expansion plan and built a high-standard, high-speed bottle cap pad insertion production line. The target capacity was set at 150 pcs/min, and the core processing link adopted 33mm thin aluminum foil for pad insertion and sealing.

During the production line planning and trial operation phase, the enterprise found that the single/double sheet detection of aluminum foil pad insertion had become a key bottleneck restricting the production line efficiency. Due to the small size of aluminum foil pads and the signal capture pressure caused by the high-speed operation of the production line, the detection solution needed to balance speed and accuracy. If this problem could not be solved, it would directly affect the release of production line capacity and product qualification rate. After multiple investigations and comparisons, the enterprise finally selected the Atonm MDSC-2100L Metal Double-sheet Detection Controller as the core solution.

2. Core Customer Requirements

Adapt to the high-speed production line rhythm of 150 pcs/min to ensure no delay in detection response.

Accurately identify the single/double sheet status of 33mm thin aluminum foil.

The equipment is small in size, can adapt to the compact space of the production line, and is easy to install without affecting the original layout.

Support long-term continuous operation, with strong stability, to reduce maintenance downtime.

3. Solution: MDSC-2100L Metal Double-sheet Detection Controller

3.1 Product Selection

Speed Matching: The response speed of the MDSC-2100L Double-sheet Detector reaches 1200 pcs/min, far exceeding the customer's production line requirement of 150 pcs/min, and fully covering high-speed detection scenarios.

Accuracy Adaptation: The equipment can detect aluminum sheets with a thickness of 0.01-0.1 mm, and the high-sensitivity single probe can accurately identify the single/double sheet status of 33mm small aluminum foil.

Flexible Installation: Equipped with a small M12 probe (12mm in diameter), it can be easily embedded in the compact space of the production line without modifying the original equipment layout.

Stability and Reliability: The production line has stable performance, supports long-term continuous operation, and adapts to the 24-hour non-stop operation demand of bottle cap production.

3.2 Implementation and Deployment

Installation and Commissioning: According to the production line layout, the technical team installed the M12 probe above the bottle cap conveying channel and fixed the main unit on one side of the conveyor belt.

Linkage Control: Connect the equipment output signal to the production line PLC system. When double sheets are detected, the production line shutdown alarm is triggered immediately to prevent unqualified products from flowing into the next process.

4. Implementation Effects

Detection Efficiency: Fully adapts to the high-speed production line rhythm of 150 pcs/min, with no delay in detection response, and the production line runs smoothly without jams.

Detection Accuracy: The problem of double-sheet pad insertion is completely eliminated, downtime is reduced, and the production efficiency of the production line is improved.

5. Customer Feedback

"The biggest concern about the new production line is the detection accuracy at high speed, and the MDSC-2100L has completely exceeded expectations. It is not only easy to install, but also detects quickly and accurately. It allows our 150 pcs/min production line to maintain high efficiency while stably controlling quality, which greatly reduces rework and loss costs. It is a 'reassurance' for our high-speed production line."

— Production Workshop Supervisor of the Bottle Cap Enterprise

The MDSC-2100L Double-sheet Detector has achieved results in multiple high-speed production line scenarios with its advantages of high-speed response, accurate detection and flexible adaptation. If your enterprise also faces problems such as thin sheet detection and high-speed production line adaptation, please refer to this case and contact us to obtain an exclusive solution!