One of the largest U.S. spirits producers was experiencing frequent stacked-down bottle incidents on its high-speed 50 ml bottle production line. Fallen containers accumulated and layered on top of one another, creating persistent down bottle detection and removal challenges. These stacked bottles interrupted production, required operator intervention, and reduced overall spirits bottling line efficiency.
Morrison installed two Down Bottle Reject (DBR) systems in sequence on the production line to create a robust automated down bottle removal solution. The first DBR unit removed the top downed bottle, and the second cleared the remaining container. This dual-reject bottle handling configuration allowed the line to manage both stacked and single down bottle incidents without disrupting production flow.
The Down Bottle Reject system performed effectively with both empty, uncapped bottles and full, capped bottles. In full capped bottle applications, a single DBR unit was sufficient to address down bottle events, demonstrating the flexibility and scalability of Morrison’s custom container handling solutions.
The system was designed to integrate with the OEM and customer control architecture, allowing the producer to incorporate the reject equipment into its existing line controls. This approach combined Morrison’s mechanical container handling design with the customer’s established automation platform, supporting coordinated operation across the bottling line.
The bottle handling system featured a single-lane Down Bottle Reject Rail Core Plate assembly constructed from 304 stainless steel, with right- and left-side core plates and mounting hardware. A dedicated setup fixture established precise core plate positioning, while color-coded identification supported accurate adjustments for different container sizes.
Each single-lane Down Bottle Reject Rail assembly included right- and left-side reject rails up to 24 inches in length. The reject rails were manufactured from ¾-inch colored UHMW and paired with 304 stainless steel spacers to support durability, sanitation, and long-term performance in beverage production environments. A tool-less changeover design allowed operators to quickly adjust for varying bottle sizes, reducing transition time between production runs and supporting efficient bottle line changeovers.
The dual Down Bottle Reject system significantly reduced stacked bottle accumulation and minimized production interruptions on the 50 ml spirits bottling line. By automatically detecting and removing both single and layered down bottle events, the automated bottle reject system reduced operator intervention and supported more consistent line throughput across beverage packaging lines.
Every production line handles down bottles differently. Evaluating your current approach can uncover opportunities to improve efficiency and minimize disruption. Start the conversation.
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