Downtime on a bottling line is expensive. Most jams occur due to:
Star Wheel Misalignment: Ensure the star wheels are timed perfectly with the conveyor.
Inconsistent Preforms: If using a blow-molding unit, check that preform quality is consistent; warped bottles will snag in the capper.
Sensor Dust: Wipe down the photo-electric sensors on the conveyor line daily; dust from the factory floor can cause "ghost" stops.
| Issue | Potential Cause | Recommended Action |
| Water Overfilling / Spilling | Level sensor malfunction or foam buildup. | Clean the level sensors; check if the air exhaust tube in the filling valve is clogged. |
| Capper Not Sealing | Worn-out capping head or incorrect torque. | Inspect the grippers inside the capping head; adjust the magnetic torque setting. |
| Bottle Crushing | Misalignment of the star wheel or conveyor speed. | Ensure the bottle neck sits flush in the gripper; synchronize conveyor speed with filler RPM. |
| Noisy Operation | Lack of lubrication or loose mechanical parts. | Check the central lubrication system; tighten the main drive chain/belt. |
To ensure the longevity of your membranes and water quality, follow this daily routine:
Pressure Monitoring: Check the inlet and outlet pressure gauges. A significant drop usually indicates a clogged filter.
Conductivity/TDS Check: Test the treated water TDS daily to ensure it meets your required standards (e.g., <50 ppm).
Dosing Pump Inspection: Ensure antiscalant and pH correction chemicals are at adequate levels.
Logbook Entry: Record flow rates and pressure readings; this is vital for warranty claims and identifying performance trends.
Replacing membranes too early is a waste of money; replacing them too late damages your pumps. Look for these signs:
Permeate Quality: A 15–20% increase in TDS levels in the output water.
Feed Pressure: If you need significantly higher pressure to maintain the same water output.
Cleaning Frequency: If you find yourself needing to perform a CIP (Clean-In-Place) more than once every 3 months.
| Issue | Potential Cause | Recommended Action |
| Whitening of Bottle (Stress) | Preform heating temperature is too low. | Increase the voltage/temperature of the infrared heaters in the oven. |
| Bottle Bursting in Mold | Overheating or weak preform quality. | Reduce heater intensity; check preform wall thickness consistency. |
| Poor Bottom Formation | Insufficient blowing pressure or blocked vents. | Check the high-pressure air compressor (should be ~30 bar); clean the mold exhaust vents. |
| Uneven Wall Thickness | Stretch rod timing or misalignment. | Calibrate the stretch rod stroke; ensure the preform is centered perfectly in the mold. |
| Issue | Potential Cause | Recommended Action |
| Low Permeate (Output) Flow | Clogged pre-filters or fouled membranes. | Replace 5-micron spun filters; perform a CIP (Clean-In-Place) on the membranes. |
| High Output TDS | Membrane bypass or O-ring failure. | Inspect the pressure vessel O-rings; check if membranes have reached their end-of-life (approx. 2 years). |
| Pump Vibrating Heavily | Air trapped in the line or cavitation. | Bleed the air from the pump head; check if the raw water feed pressure is too low. |
| High Pressure Drop | Scale buildup on membrane surface. | Increase the antiscalant dosing rate; check the frequency of the auto-flush cycle. |