Dual detection of bottle cap aluminum foil gasket | MDSC-2100L solves the problem of stacking ultra-thin gaskets

1、 Project Background

In the fields of food and pharmaceutical packaging, the sealing quality of bottle caps is directly related to the shelf life of products. A high-end bottle cap production enterprise may produce double gasket non-conforming products during the aluminum foil gasket insertion process due to the thin and light gasket that is prone to lamination. The flow of unqualified products downstream will cause quality risks such as inconvenient opening and leakage. The enterprise originally used two quality inspectors for manual screening, with an annual labor cost of 80000 yuan, and the annual cost of material loss generated during the rework process reached 72000 yuan. The 0.8% missed inspection rate still poses a quality hazard, so an automated testing plan is urgently needed.

2、 Working condition analysis

The testing object and production line parameters of this project have clear requirements for the equipment:

Material characteristics: The outer diameter of the aluminum foil gasket is 22mm, the total thickness is 0.05mm, and the metal layer is only 0.02mm. It belongs to the ultra-thin detection scenario, and conventional sensors are prone to misjudgment

• Production line rhythm adaptation: The filling speed is 100 pieces/minute, and the response speed of the detection equipment needs to match the production line rhythm to avoid missed detection or false rejection due to delay.

• Limited installation space: The existing padding equipment has a compact structure, and the sensor needs to be small in size and flexible to install.

3、 Solution: MDSC-2100L Single Probe Single/Double Sheet Detection Sensor

In response to the challenges of the above working conditions, the technical team has conducted multiple rounds of scheme demonstration and finally selected the Atorm single probe metal double detector MDSC-2100L metal single double detector as the core solution. Its technical characteristics are highly compatible with the project requirements

1. Technical advantages of equipment

The MDSC-2100L metal single and double detector adopts customized high-sensitivity electromagnetic induction technology, suitable for detecting ultra-thin metal materials. According to the product parameters, its detection thickness range covers 0.01-0.1mm, which can meet the detection requirements of the 0.02mm metal layer this time; The response speed reaches 1200pcs/min, which is 12 times the actual production line speed (100 pcs/min) and can meet the high-speed detection requirements. High sensitivity small probe sensors can be installed and used even on devices with compact internal structures.

2 Product installation details

Sensor selection and installation: Select M12 single probe SE-2100LC-F6.0 (diameter 12mm x length 35mm), suitable for compact space on the pad table. The probe is installed in conjunction with the cylinder through a customized bracket. When the bottle cap is inserted into the pad and rotated to the detection position with the pad table, the cylinder pushes the probe to contact the bottle cap to quickly complete single and double piece detection; After the detection is completed, the cylinder drives the probe to reset, ensuring that it does not affect the continuous rotation rhythm of the pad table.

Signal linkage and rejection: Integrate the MDSC-2100L metal single and double detector controller into the production line PLC system and synchronously connect it to the photoelectric switch in place. After the bottle cap triggers the in place signal, the dual controller completes signal acquisition and analysis within 10ms. If it is determined to be a dual gasket, it immediately sends a signal to the pneumatic removal device, and accurately pushes the non-conforming products into the collection box through the side blowing air nozzle. The removal response time is controlled within 50ms to ensure that it does not affect the subsequent bottle cap transportation rhythm.

4、 Customer revenue

MDSC-2100LAfter 3 months of operation, the metal single and double detector equipment showed significant improvement in production line data, achieving synchronous improvement in quality control and production efficiency

• Quality control improvement: Unqualified products with double gaskets entering the cover have been effectively controlled, with a leakage rate of 0, significantly reducing sealing quality complaints caused by lamination. The number of sealing complaints from downstream customers has decreased by 92% compared to before.

Production efficiency improvement: The daily effective production capacity has increased by about 1200 units, and based on an annual production of 300 days, the annual new production capacity is 360000 units.

Good equipment stability: easy and efficient production and debugging, improving the flexibility level of multi specification bottle cap production.

5、 Summary

In this case, the AtonmMDSC-2100L metal single and double detector has solved the problem of stack detection for 0.02mm ultra-thin aluminum foil gaskets through customized application, providing a replicable solution for fine quality control in the packaging industry. Its core value lies in achieving effective detection through high-sensitivity detection technology, and meeting the adaptation requirements of the production line with compact design and fast response.

For industries such as food and medicine that require high sealing quality,MDSC-2100LThe metal single and double detector has strong scene adaptability, which can meet the detection needs of ultra-thin and small gaskets, as well as the rhythm requirements of medium and high-speed production lines, providing technical support for enterprises to balance cost reduction, efficiency improvement, and quality upgrading.