Fill management



Finding fill level and closure faults and exposing the causes:  filler and closer management.

Ensuring highest product quality with maximum filler and closer efficiency – the HEUFT SPECTRUM VX manages it!  Proven functions for checking and inspecting full containers safeguard the quality of the products.  The system uncovers losses in filler and closer performance before this can impair the efficiency of the complete line using an integrated quantifying system, serial fault detection and continuous monitoring.


Fill level detection

Finding underfills and overfills reliably:  the right technology for each application.

Too little, too much or exactly right:  the HEUFT SPECTRUM VX can be perfectly equipped with different detection modules for a precise fill level detection.


It checks the filling quantity of transparent bottles with special optical procedures highly precisely.  The high frequency measurement provides exact results for all types of non-metal containers – and compensates foam which may be present in the course of this.  This reduces the false rejection rate on filling lines for beer or carbonated soft drinks.  
X-ray technology for determining the filling quantity exactly is used if the containers are opaque.  An integrated quantifying module converts the results of the individual fill level measurements automatically into the actual fill value and calculates the average fill volume.



Closure detection

Ensuring tightness: different possibilities for a closure check.

Effective, safe and precise:  different technologies for a closure check can be integrated into the system due to its modular construction.  It can check the presence, position, completeness, integrity and brand affiliation of the closures precisely with special sensor, camera or ultrasonic technology depending on the requirements.  Thus it provides the best results for every application and safeguards the tightness of the bottle sustainably as well as the quality contained in it.


Filler and closer management

Finding faults and exposing the causes:  monitoring the filler valves and the closer heads.

Detecting, monitoring and locating:  finding faulty filling and closure faults reliably is one thing.  However it is just as important to uncover their causes at an early stage for the sustainable safeguarding of product quality and productivity.


The HEUFT SPECTRUM VX takes over the monitoring of the filler valves and closure heads for this purpose.  It monitors their performance continuously and provides exact statistical data.  Malfunctions which can cause serial faults are therefore identified in good time.  The system already exposes defective valves and closure heads before they completely fail.  This permanent filler and closer management system is a valuable tool for preventive maintenance.



Bottle burst management

Detecting and competently managing burst bottles:  effective protection against contamination due to glass splinters.

Detection, reaction and prevention:  the potential danger of glass bottles which burst in the filler should not be underestimated.  The HEUFT SPECTRUM VX registers burst bottles immediately and draws the right conclusions:  not only are these rejected but also adjacently filled bottles and those which have been filled during the subsequent circuits with the same valve.  Therefore products contaminated with glass splinters cannot reach the customer.


Furthermore an optional forced underfill can prevent them from being inadvertently returned to the production flow.  Another safety factor is provided by the shower function which cleans the areas which could be contaminated with glass splinters.



Automatic sampling

Checking production quality regularly:  exemplary sampling.

Controlled, individual and representative:  the HEUFT SPECTRUM VX carries out exemplary sampling for internal quality assurance purposes.  Cross-sectional sampling of production is possible due to the freely definable rejection of the desired number of containers or a whole series of bottles in succession.


These can be selected separately for targeted sampling in order to check individual filler valves or closer heads specifically.  In addition it is also possible to define particular conditions such as minimum speed in order to take representative samples under standard production conditions.



Container distribution

Dividing up the production flow:  distribution onto several lanes.

Specific, even and effective:  the HEUFT SPECTRUM VX distributes the container flow onto up to seven transport lanes if required.  The distribution ratio is freely selectable and adjustable.  Special jam switches ensure an even utilisation of the lanes – full conveyor sections are identified and excluded from the laning process.  The result:  considerably better efficiency for the whole line.


Fault rejection

Preventing recalls:  the reliable rejection of faulty containers.

Fast, careful and accurate:  highest precision when detecting faults is only effective if the products in question are also removed afterwards.  The single-segment and multi-segment rejection systems of the HEUFT rejector series deal with this both precisely and carefully.


Product monitoring and self-tests

Playing it safe:  exact product tracking and regular self-tests.

Always knowing the current location of a particular product:  each one is tracked precisely for this.  This ensures that none remain uninspected.


The integrated reject verification checks that each product identified as faulty is really removed.  Standard test programs guarantee a regular examination of the detection performance.  Network-based continuous documenting and long-term archiving of the results.


Optional additional functions

Detecting even more:  extensions to the range of functions.

The HEUFT SPECTRUM TX systems with their modular design can be extended at any time.  Therefore the range of functions of the HEUFT SPECTRUM VX can be extended with technologies for checking the presence and position of labels.  Furthermore the following can be integrated without any problems:  the HEUFT vio OCR for an optical inspection of best-before dates and barcodes.


In addition the HEUFT VISION module carries out a high-precision optical closure inspection as an option.  The HEUFT sonic checks the tightness of metal closures.  This can also be optimally achieved when extending it with the HEUFT magnetic tracking when the closures of different manufacturers are used.  The HEUFT O2 add-on detects residual air in the bottle which causes the product to spoil prematurely e.g. in the case of unpasteurized beers.
The acoustic burst bottle detection, available upon request, can even uncover partially burst bottles reliably.





Controlling centrally:  one platform for all requirements.

Precise, network-compatible and cross-system:  the HEUFT SPECTRUM TX forms the basis for different technologies, modules and functions.  The devices of the generation of the same name can be exactly adapted to individual requirements on site and retrofitted at any time due to this universal platform.


A cross-system component equality of 70 per cent ensures a high availability of spare parts.  The central HEUFT SPECTRUM TX control unit creates a high level of precision during continuous product tracking and quality assurance due to its multiprocessing capability.  A future-proof network connection ensures reliable remote maintenance and production data acquisition for optimum efficiency and productivity.  In-house developed hardware and software and its own operating system ensure computing power and offer no opportunity for viruses or malware.


HEUFT reflexx

Combining photographs and reliably detecting objects:  image processing in real time.

Fast, powerful and exact:  combining several camera and X-ray images with each other and specifically detecting various objects.  The HEUFT reflexx carries out all this in real time.


The in-house developed hardware and software provides high computing capacity and is exactly tailored to the requirements of the in-line quality inspection.  It generates high-resolution, noiseless detection pictures and analyses them precisely.  Integrated filter technologies clearly differentiate between supposed and actual faults.  This reduces the false rejection rate sustainably.



Operating HEUFT systems reliably:  graphical user interface with practical tools.

Clear, helpful and specific:  the HEUFT PILOT graphical user interface convinces due to an easy to understand, multilingual menu structure with extensive auxiliary tools.  Therefore the reliable operation of the HEUFT SPECTRUM TX systems is not difficult.


Important information and clear error messages with service notes provide the respective user with specific support.  This avoids incorrect adjustments and shortens standstills e.g. during brand changes.  Password protected operator levels adapted to the respective area of responsibility also contribute to this.  Also integrated:  a complete online user manual and a tool for the uncomplicated identification and direct ordering of spare parts.



Network technologies

Networking everything:  online connection for increased efficiency and quality.

Information transmission in real time, production data acquisition, line analysis and remote maintenance:  networking is the answer!


HEUFT systems have future-proof network interfaces (Gigabit Ethernet and TCP / IP) for an online connection via the Internet and the database interface (SQL / DDE) for top line efficiency and an optimum quality management with considerably faster and easier workflows.  Therefore production data, shift records, productivity faults and HACCP limit value analyses are available network-wide.  The result:  early identification of quality and efficiency problems.  The firewall protected direct connection to the HEUFT TeleService makes competent remote maintenance possible all around the clock.


HEUFT rejector

Removing faulty products:  the right rejector for all cases.

For example, the single segment HEUFT flip and HEUFT mono rejectors as well as the HEUFT DELTA-K and HEUFT DELTA-FW multi-segment systems are ideally suited for the HEUFT VX.

Learn more...

  • reliable detection of all the critical faults during the filling process
  • avoidance of costly production downtimes due to the early diagnosis of filler and closer malfunctions
  • optimal instrument for preventive maintenance
  • reliable determination and statistical processing of the average fill volume
  • effective protection against contamination due to glass splinters in the case of burst bottles
  • performance range – up to 100,000 containers per hour
  • minimisation of the false rejection rate of up to 0.01%