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Line Audit Series – Client Case Study No.5

Preventing a Small Inefficiency from Becoming a Big Headache:
A Line Audit of Ionized Air Can Rinsers and Twists Results in Optimal Productivity

Sometimes a small inefficiency can become a big problem. That was the case with a valued Entech that was encountering occasional jamming with a can twist. The client runs two lines with Entech Gatling ionized air can rinsers at speeds 1250 cpm. The volume through these two lines exceeds 7 MM cans processed per week — 1250 cpm, 2 shifts per day, 6 days a week.

To remedy the situation, a member of our sales and technical team offered to visit the facility in order to see the twist first-hand. At this time, our team member also provided an overall review of the client’s two can rinsing lines in order to fully evaluate the issue at hand and identify any other potential problems.

Undetected Wear and Tear
Upon inspection, our Entech technician explained to the customer that the top metal rail of the twist had become worn with use, resulting in a “looser” fit through that area of the twist. This “looseness” was causing the cans to gap and collide together — creating occasional line jams. This type of wear is not always visibly obvious and could easily go undetected — allowing the line interruptions to get worse over time. However, based on our experience, Entech’s technical staff is able to quickly identify exactly where problem areas are located.

Further inspection of both lines revealed other areas with similar wear, along with additional issues that needed attention to prevent unnecessary downtime. The can rinsers and can twists had been installed 3 and 7 years prior, and while the speeds were still running 1250 cpm, the occasional jamming and colliding was causing intermittent slowdowns — the can lines were not running as efficiently as they were designed to be.

A Preventative Maintenance Plan
After the audit, our Entech sales team worked with the client to put together a comprehensive preventative maintenance plan to submit to the corporate office. The plan included installation of several new can twists and replacement of all rails throughout both can rinsers. Since all the twists and rails were originally installed at the same time, this plan would prevent multiple future shutdowns that would be necessary to replace individual can twists or rail sections as further wear developed.

This plan was then put into practice. Being proactive and planning for maintenance allows our client to avoid potential crisis shutdowns that could occur in the middle of a run. Additionally, keeping the equipment in top condition allows the client’s can lines to maintain full speed and optimum productivity.

Entech is committed to sharing knowledge acquired in our 40+ years of serving the canning industry. As part of this effort, we are sharing some of those insights in our Line Audit Series — based on actual audit case studies. If you’re curious about the lifetime of your line’s twists and rails, or other rinsing components, give our Entech sales team a call to discuss how a complimentary line audit might benefit your organization. Contact us today.