MAGNET - URD - 3 Beta PDF

EMEA F&HC Engineering
Magnet
Line 9
User Requirements Document (URD)
Version 2
16 November 2007
This document contains information proprietary to Procter & Gamble. It is not to be disclosed to third parties or used other than for
the purposes for which it is furnished without the prior written consent of Procter & Gamble.
20076 P&G
Line 9
User Requirements Document
November 2007
Revision History
Date
Version
Description
Author
11.8.2007
1beta
DRAFT
Chrastny&Vins
11.16.2007
2beta
draft
Chrastny&Vins&Krau
z&Safranek
Legenda
..... was made by Mr.Vins and need to be discussed
Controlled Distribution
Reviewer
Company-Location
e-Mail
Organization
Date
Phone #
Mobile #
Safranek Stanislav
GianCarlo DeNadai
Martin Chrastny
Miroslav Manur
Vlasta Krauz
Approvals
Name
Signature
Mirek Manur
Vlasta Krauz
Property of Procter & Gamble - Confidential
Page 1 of 26
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November 2007
Table of Contents
1
About this Document ..................................................................................................................................3
Project scope .................................................................................................................................................3

2.1
C&IS System Strategy ............................................................................................................................... 3
2.2
C&IS Software Standards .......................................................................................................................... 3
Process Description ....................................................................................................................................4

3.1
Overview ......................................................................................................................................................4
3.2
Key Parameters...........................................................................................................................................1
3.3
System architecture ...................................................................................................................................1
3.4
Line PLC configuration ............................................................................................................................... 1
Operating Requirements ........................................................................................................................... 2

4.1
Start Up ........................................................................................................................................................ 2
4.2
Steady State Operation .................................................................................................................................3
4.3
Start Up Types ..............................................................................................................................................4
4.4
Shutdown / Restarting...................................................................................................................................4
4.5
Operator Adjustments in Automatic .............................................................................................................5
4.6
Manual Operation .........................................................................................................................................5
4.7
Change Over .................................................................................................................................................5
Exception handling / Alarming ...............................................................................................................6

5.1
Alarms .......................................................................................................................................................... 6
Human Machine Interface Requirements ......................................................................................................8
6.1
Display Navigation .......................................................................................................................................8
6.2
Screens ........................................................................................................................................................ 9
6.3
Other Interface Requirements: .............................................................................................................. 11
Safety System Functions ................................................................................................................................ 12

7.1
Safety System Strategy ........................................................................................................................... 12
7.2
Safety System Hardware ......................................................................................................................... 13
Size System Management............................................................................................................................... 15
DownTime Tracking System (MES) ............................................................................................................. 16
Page 2 of 26
Line 9
November 2007
About this Document
This document provides functional requirements for the Magnet line 9 controls. It describes how the process has to
operate from a user perspective. It provides a basis for designing the control systems logic and human interface,
reporting and data sharing.
2
2.1
Project scope
C&IS System Strategy
Controls principles that shall be used on this project include but not limited to:
Utilize Rockwell family of programmable logic controllers.

Risk assessments shall be completed by the OEM in cooperation with P&G to determine the correct level of
safety for the machine.
Selection of electrical devices shall be provided by the electrical specification for the project. If the selection of a
device cannot be determined by the electrical specification, the PC&IS engineer on the project will work with the
OEM to determine the best technology fit for the application.
Application/ Performance requirements shall be utilized foremost in selection of electrical components on the
machine and shall at no time jeopardize the safety of company personnel.
2.2
C&IS Software Standards
Software standards on this project shall include P&G Low Cost Programming and Configuration Guidelines
for Rockwell Compact Logic.
Page 3 of 26
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3
3.1
November 2007
Process Description
Overview
The packing line in producing FE bottles for different sizes and flankers. Its capable of producing packed bottles at a
speed of 300 bt/min on 0.5 liter size. Line consist out of:
-
1 LPD unit (late product differentiation unit)
1 unscrambler
1 fillers (Tech Long)
coding device (bottle printing, case printing, pallet labelling )
bottle weighing/reject system
Labeller
Case packer (case erector, case sealer, case packer)
Case weigher/reject system
Palletising unit (stretch wrapper)
Airveyors for connecting the different machines
Simple block diagram
Case
erector
Unscra
Labeller
mbler
Filler/capper
Case
Tech Long
packer
Palletizer
Stretch
wrapper
Page 4 of 26
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3.1.1
November 2007
BLOCK DIAGRAM
The total lay out is made out of different machines with different functions or transformations for each machine.
Each machine has his own controller, a line controller controls empty bottle infeed to unscrambler, interconnection
between machines, pallets roller conveyors and will be used as interface to a line operator.
Liquid FE will be delivered with a centrifugal pump to the filler. The filler receives bottle from the labeller, which is
filled from unscrambler, and will fill the bottle. A cap is placed on the bottle with a certain torque. Bottle will than go to
a bottleprinter and a checkweigher. Not OK bottles (based on weight) are rejected. OK bottle will pass to the case
packer. In the casepacker the cases will be formed out of carton folded into cases and filled with 6/12 bottles. The
case will be sealed and pass the case printer. After the caseprinter the case will be checked for weight (no missing
bottle). From the case weigher the case will arrive in the palletising.
Page 1 of 26
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November 2007
PH2
No bottles
Bottles
Bottle hopper
PH1,PH3
Bottle regulation
PH4
Start/Stop unsc.
Unscrambler
PH11,PH12
Start/Stop Harland
AIR Conveyors
Filler rejection
system
PH13
Stop Harland
Labeller
PH22
Stop Filler
Product
Filler
Labels
Vision system
+ Reject
PH41
Stop Filler
Conveyors
Diverter
Bottle weigher
+ Reject
Cap-sorter
Caps
Page 1 of 26
PH21
Stop Filler
AIR Conveyors
Line 9
November 2007
Cartons Glue
Rejection
PH42
Stop CasePacker
Case Packer
Ink
Case weigher
Roller
conveyors
Stretch
wrapper
Conveyors
Case InkJet
PH64
Stop StretchWrapper
PH66
Start Labelling
Roller
conveyors
Pallet labeller
Folie
Pallets
PH43
Stop CasePacker
Labels
Page 2 of 26
Tie sheets
Palletizer
Line 9
3.2
November 2007
Key Parameters
Item
Comment
BOTTLE CAPACITY & DIM.
1000ml
2000ml
750ml
500ml
1500ml
INTERNAL RSC SIZES

REQUIRED SPEED
MAX PRODUCTION SPEED
For the 1000ml bottle:
250 b.p.m. (21 cases/minute)
150 b.p.m. (25-27 cases/minute)
Page 1 of 26
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3.3
November 2007
System architecture
Every component connected to network must be specified.
Line PLC
LPD
Production LAN
Air-conveyors
Labeller
Filler
Diverter
Casepacker
Page 1 of 26
Palletizer
Stretchwrapper
Line 9
3.4
November 2007
Line PLC configuration
Line PLC configuration will be better specified after completing of electrical design.
PLC Rack Configuration

Quantity
Part Number
Description
1769-L32E
Compact Logix Processor with Ethernet
1769-PB4
Compact 1769 Expansion I/O Power Supplies
1769-IQ32
Compact 32 Point, 24vdc, Sink/Source Input Module
1769-OB32
Compact 32 Point, Solid State, 24vdc, Source Output Module
1769-SDN
Compact DeviceNet Scanner
1769-ECR
End Cap Resistor/Terminator
Communication Configuration
Quantity
Part Number
Description
22-COMM-D
DeviceNet connection for Power Flex Drives for connecting up to five Drives
1761-NET-AIC
AIC+ ADVANCED INTERFACE CONVERTER. RS232 to RS485 converter
1747-AIC
RS 485 isolating module
Inside controller
Ethernet port for connecting to Line Network.
Page 1 of 26
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November 2007
Operating Requirements
4.1
Start Up
The following describes the start up of the operation from a cold, first start condition in Automatic.
Details
1.
Before starting check if there is any material, tools or so on belts or inside machines
2.
According to production order check proper packing standard (IPS) of product, recheck it according to
example and sign.
3.
Switch on STRETCH WRAPPER. Reset machine alarms, put in automatic mode.
4.
Switch on PALLETIZER (open air). Reset machine alarms, put in automatic mode.
5.
Switch on CASEPACKER (open air). Reset machine alarms, put in automatic mode.
6.
Switch on LINX and MARKEM. Reset machine alarms, put in automatic mode.
7.
Switch on UNSCRAMBLER and LABELLER (main switch and air supply). Reset machine alarms, put in
automatic mode.
8.
Power up main switch on cabinet for FILLER and CAPPER. Reset machine alarms, put in automatic mode.
9.
Open air supply for FILLER and CAPPER.
10. If necessary do the sanitization following valid SOP

11. Open product inflow on LPD HMI.
12. Open product inflow by the tank and filter.
Page 2 of 26
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4.2
November 2007
Steady State Operation
The machines run at steady speed. Filler speed is set to nominal speed 250 bt/min for 1 L. Other machines speed is
set slightly higher to ensure enough bottles infeed and outfeed.
Reactions to photocells activation:

Mark
Function
Maple
PH1 ( LG )
No bottles in lower conveyer
yes T
PH2 ( LG )
No bottles in hopper
Yes T
PH3 ( PACE )
Regulate infeed of bottles to unscrambler

disc by LG
PH4 ( PACE )
Jam detection. Start - Stop the

unscrambler. [Time is parameter]
Yes
PH11 ( Harland )
Start Harland
PH12 ( Harland )
Stop Harland, no input bottles
Yes
PH13 ( Harland )
Stop Harland, full output
Yes
PH21 ( Techlong )
Stop Techlong, no input bottles
Yes
PH22 ( Techliong )
Stop Techlong, full output
Yes
PH41 ( TMG )
Stop Techlong, full bottles
Yes
PH42 ( TMG )
Start - Stop TMG, no bottles
Yes
PH43 ( TMG )
Stop TMG, full output of cases
Yes
PH61 ( LG )
Pallet is on turntable
Yes
PH62 ( LG )
Yes
PH63 ( LG )
Yes
PH64 ( LG )
Yes
PH65 ( LG )
Pallet is before labeller
Yes
PH66 ( LG )
Pallet is in the labeller
Yes
PS61 ( LG )
Possition turntable 1
Yes
PS 62 ( LG )
Yes
PS63 ( LG )
Yes
PS 64 ( LG )
Yes
Page 3 of 26
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4.3
November 2007
Start Up Types
Starting of the Line conveyors is dependent on states of photocells only.

4.4
Shutdown / Restarting
Normal Stop: The operator can independent stop all machines by pressing STOP button. Machines are
stopped normally. This means that machines stop in feed of bottles, finish operation (filling, labeling,
packing) and stop all movements. All bottles and cases are out of the machines.
E-Stop: The E-Stop are split into the machine level. E-STOP stops only particular machine.
Complete Stop: Complete stop is used on end of production batch (before product or size changeover).
Complete stop is closely described under this table.
Restarting: Production can be resumed from a Normal or E-Stop by pressing a start on the line HMI. After
E-Stop operator must restart Emergency circuits on all machines first.
Complete stop complete line empty

1.
Going out all bottles from container, unscrambler, filler, capper, case packer, palletizer and stretch wrapper.
2.
Take out label reel from reel support.
3.
Cover all empty bottles and boxes (against dust). If next production will be with another packing material, fill
return form ( vrcenka ) and pass bottles and cases to in-process store. Dont leave wrapping material and
full bottles inside machine, on the belts or on the desk.
4.
Close product inflow by the tank and filter.
5.
Close product supply on LINE cabinet.
6.
After finishing the product (empty filling nozzles) flush out filler by demi-water.
7.
Fill nozzles by demi-water.
8.
Close air supply for FILLER and CAPPER.
9.
Power off FILLER and CAPPER by main switch on cabinet.
10. Switch off UNSCRAMBLER and LABELLER (main electrical switch and air supply)
11. Switch off LINX and MARKEM.
12. Power off CASEPACKER by main switch (close air supply).
13. Power off PALLETIZER by main switch (close air supply).
14. Switch off STRETCHWRAPPER.
15. Clean up whole line (no drops, no visible dust)
16. Close quality and reliability records in computer, close work shift in appropriate form.
Page 4 of 26
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November 2007
4.5
Operator Adjustments in Automatic
4.6
Manual Operation
The packing line does not have a system wide Manual Mode.
The line devices (Motors, etc.) can be directly operated by the technician at any time. This is provided for
maintenance, check out and troubleshooting not as a routinely used operational feature.
4.7
Change Over
Follow valid SOP
Page 5 of 26
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November 2007
Exception handling / Alarming
5.1
Alarms
Alarm
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
Input
Description
SAFETY BLOCK OF EMERGENCY SHUT-DOWN SWITCH OFF
EMERGENCY STOP SWITCHBOARD DOOR =RM?
EMERGENCY STOP SWITCHBOARD DOOR =RM?
EMERGENCY STOP OPERATION BOARD
EMERGENCY STOP 1
EMERGENCY STOP 2
EMERGENCY STOP 3
EMERGENCY STOP 4
BIAS VOLTAGE PROTECTION
RESERVE
L8 - SB01 (BOTTLE HOPPER) POWER SUPPLY
ROLLER CONVEYER SR30 POWER SUPPLY
RESERVE
RESERVE
TURNTABLE ST30 POWER SUPPLY
RESERVE
L8 - BOTTLE HOPPER FAILURE
L8 - LABELLER FAILURE
L8 - FILLER FAILURE
L8 - DIVERTER FAILURE
L8 - CASEPACKER FAILURE
L8 - CASE REJECTION FAILURE
L8 - PALLETIZER FAILURE
L8 - STRETCHWRAPPER FAILURE
L8+L9 - PALLET LABELLER FAILURE
RESERVE
L8 - INK JET LINX FAILURE
Page 6 of 26
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November 2007
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
80
81
82
83
84
85
86
87
88
89
90
91
92
93
84
85
96
97
98
DN
DN
DN
DN
DN
DN
DN
DN
DN
DN
DN
DN
DN

L8 - DOMINO MACRO JET FAILURE
L8 - VISION SYSTEM FAILURE
L8 - CHEKWEIGHTER (FULL BOTTLE) FAILURE
L8 - CASE WEIGHTER FAILURE
L8 - LPD FAILURE
RESERVE
RESERVE
RESERVE
L9 - BOTTLE HOPPER FAILURE
L9 - LABELLER FAILURE
L9 - FILLER FAILURE
L9 - DIVERTER FAILURE
L9 - CASEPACKER FAILURE
L9 - CASE REJECTION FAILURE
L9 - PALLETIZER FAILURE
L9 - STRETCHWRAPPER FAILURE
RESERVE
RESERVE
L9- INK JET LINX FAILURE
L9 - DOMINO MACRO JET FAILURE
L9 - VISION SYSTEM FAILURE
L9 - CHEKWEIGHTER (FULL BOTTLE) FAILURE
L9 - CASE WEIGHTER FAILURE
L9 - LPD FAILURE
RESERVE
RESERVE
RESERVE
DEVICE NET MASTER ALLARM
DEVICE NET -NODE 1 - ERROR
RESERVE
RESERVE
L8 - SB01 (BOTTLE HOPPER) DEVICE NET ERROR
RESERVE
RESERVE
RESERVE
RESERVE
RESERVE
RESERVE
Page 7 of 26
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6.1
November 2007
Human Machine Interface Requirements
Display Navigation
There are 2 levels of menus within the HMI screens, which provide machine control for the filler.
First level of control is the main screen. This screen shall have targets which allow the operator
to navigate to the second level of screens. All sub-screens shall have return to main screen
targets for rapid escape functionality.
Main Screen
1.
2.
3.
4.
1st Level
Selected format
Alarm Status
Number of produced pallets
Language selection
Setting
2nd Level
1.
2.
3.
4.
5.
Frequency inverters fault reset

Set/Reset printer checking
Set/Reset cap detection
Set/Reset bottle underweight detection
Return
Production
1.
2.
3.
4.
5.
Format selection
Number of pallets produced / to be produced
Number of produced cases
Raw material needed to complete production
Return
Conveyors
1.
2.
Conveyors speed
Return
Signals
1.
2.
Generic Screen
Requirements
Help Screens
Status of Equipment
Return
HMI will remain on the screen selected by the operator until either the operator moves off of
the screen, ten minute timer completes which returns to the main screen, or if the power is
cycled.
HMI Screen colors and nomenclature shall be consistent throughout all screens.
Alarm list shall be viewable at all times, located at the bottom of the screen and provide
scrolling capability, permitting operators the ability to scroll through the faults.
Alarms shall be displayed in a First Out alarm sequence. Alarms shall be color coded to
reflect the type, passive or stop.
Only alarms which trigger a stop require acknowledgement, once acknowledged, alarm shall
be removed from the alarm list.
2nd Level screens provide the point detail information used to change values.
2nd Level screens shall be structured in a manner which provides the existing values for the
parameters, along with the ability to change the value.
Help screens shall provide assistance in operating the machine. Screens shall follow the
same format and shall be used for assisting the operator in operating the machine.
Page 8 of 26
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6.2
November 2007
Screens
MAIN SCREEN
SETTINGS
PRODUCTION
Page 9 of 26
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November 2007
CONVEYORS
SIGNALS
Page 10 of 26
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6.3
November 2007
Other Interface Requirements:
Main Panel
HMI Screen
Emergency stop
Reset
Stop
Start
The status of the line will be indicated using a Totem Pole Lamp (Multi-State Indicator Pole and a Horn.
The operation of this status equipment will be as follows:
a) Totem pole Multi-color Lamp (Red, Yellow & Green Lights)
Red
Flashing red light
= Emergency stop
Yellow
Flashing yellow light
= Minor error (some machine not ready)
Continuous yellow light
= Line in Standby
Flashing green light
= Automatic-restart
Continuous green light
= Line working in production
Pulsing On and Off
= Emergency, Alarm
Continuous sound
= Line starting
Green
b) Horn
Horn
A delayed start with acoustic and visual warning signal prior to the start of the line.
Page 11 of 26
Line 9
7
7.1
November 2007
Safety System Functions

Safety System Strategy
Risk
Assessment
Stop Types
Circuit Design
Risk assessment should be performed to determine the risk level. This process documents the process
taken to ensure a safe machine. It also provides feedback to the design for risk mitigation. Assumed risk
level of the machine is Category 3 (Europe) = Control Reliable (US), based on the existing knowledge of
the machine and of machines similar to the machine of interest.
Machine e-stops and guard switches shall be category 1, which means when pressed or activated, there is
a deceleration of the machine to zero speed then removal of power.
Each stop type whether acted independently or together will result in the individual alarm being generated
on the HMI screen.
Circuit shall be designed to permit the users to configure the machines e-stop circuit as a zone e-stop or line
e-stop based on the risk assessment.
E-Stop Circuit shall be hardwired in series back to the Safety Relay Input 1, with individual auxiliary
contacts wired to the PLC for monitoring purposes.
Category 3 requires that all guard switches be required in series and connected to a dual channel safety
relay Input 2. This safety relay shall be wired in parallel to two safety contactors which have their
normally open outputs wired in series back to the safety relay.
Picture below shows a circuit which satisfies the requirements of a category 3 circuit.
Figure 1
PLC Monitoring
All guard switches, disconnects, E-Stops shall have one set of normally open auxiliary contacts wired back
to the PLC for monitoring. This information shall be displayed on the main screen of the HMI for status
purposes.
Page 12 of 26
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November 2007
Safety System
Logic
This section provides an overview of the logic specific to the safety system. Logic pertaining to the
different functions of the machine and how the safety system interacts can be located in the operational
function section of this document.
Logic shall provide a continuous monitoring of the safety function so that any one failure does not
compromises the safety of the machine. Startup of the machine shall be interlocked with the safety circuit
and shall not permit a startup of the machine until all requirements within the safety circuit are satisfied:
1) Safety relay indicates that the components within the safety system are operational.
2) PLC receives input from the safety relay that all doors are closed and that no e-stop has been activated.
3) PLC monitoring inputs from the guard switches indicate that all guard doors are closed, all disconnects
are in the on position and that no, E-stops have been activated.
4) Any alarms from the safety function of the machine have been reset.
7.2
Safety System Hardware
Overview
Safety Relay
Safety Contactor
Disconnects
Components which the Category 3 system is comprised of are as follows:

1. Guard Switches
2. Safety Relay
3. Time Delay Safety Relay
4. Safety Contactors
5. Disconnects
6. E-Stops
All hardware which is used within the safety circuit must be safety rated. This is indicated by the
components being colored red.
Safety relay NOT THE PLC shall be used to monitor the redundant guard door switches circuit, and the
positively guided auxiliary contacts on both safety contactors. Outputs from the safety relay provide the
signal to the redundant power contactors to open and close.
Two safety contactors in series shall be used to provide mechanical isolation of the electrical source and
the moving components on the machine. Contactors actuated by the safety relay only and shall have
positively guided auxiliary contacts that are monitored by the safety relay.
Two types of disconnects are required on the machine:

1) Main Machine Disconnect
a) BLACK Actuator with a yellow background.
b) Purpose is to remove motion bus power and logic power from the machine.
c) Typically only one, which is found on the door of the main control panel.
d) Should be labeled to indicate function.
Page 13 of 26
Line 9
E-Stops
November 2007
Actuator must be RED on a YELLOW background.

Button must be either of the palm or mushroom-head style.
2-Normally Closed Contacts, 1 normally open contact, on separate contact blocks. (see picture
below)
The actuator must be of the self-latching style.
Machine must not automatically start restart once the E-stop has been reset.
The E-stop switch must
have a positive opening operation.
Page 14 of 26
Line 9
November 2007
Size System Management
SIZE Strategy
Up to five sizes shall reside within the PLC processor. Sizes are called up from the HMI during a
changeover. At that time the processor moves the values held within the size into the appropriate
locations.
Size
Management
Screens
Size handling system will consist of a Format selection menu in Settings screen (select current
size from the available ones). In Conveyors speed and Photocells time screens the operator
will be provided with the opportunity to change the values inside a present tolerance range. If
the value entered is not acceptable, the system will reject the changes.
Parameter List
within a SIZE
See parameters table in part 4.5
Page 15 of 26
Line 9
November 2007
DownTime Tracking System (MES)
Implementation
Strategy
Terminology
Tag Location
Tag Descriptions
To provide an adequate foundation for adding downtime tracking tools used by P&G into the logic.
Alarm Warning of a pending condition. Displayed on the HMI, does not shut down the machine.
Alarms do not require reset.
Stop Code Fault which causes an immediate stop of the machine. Displayed on the HMI, does
require as reset or acknowledge of the fault.
Two types of tags must be programmed within the PLC. Location of these tags shall be provided to
P&G and shall be documented within the logic as such.
(1) State This tag provides status information on the machine. Values which make up this tag are
as follows:
1 = Run
2 = Stopped
3 = Blocked
4 = Starved
Blocked and starved are what is considered to be a paused state. This means that the machine has
not experienced a fault, but has stopped due to either a lack of bottles or that a downstream machine
has stopped running and bottles have accumulated to the out feed conveyor.
(2) Fault - the value in this tag is an alarm number for the first out stop code which is mapped to the
reason tree.
First Out stop code first stop code/ fault that caused the machine to stop. For instance if an
overload sensor is tripped and the machine stops, then an operator hits and e-stop on the machine.
First out stop code is the overload, not the e-stop.
Page 16 of 26

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EMEA F&HC Engineering

User Requirements Document

Property of Procter & Gamble - Confidential

User Requirements Document

About this Document ..................................................................................................................................3

Project scope .................................................................................................................................................3

C&IS System Strategy ............................................................................................................................... 3

C&IS Software Standards .......................................................................................................................... 3

Process Description ....................................................................................................................................4

System architecture ...................................................................................................................................1

Line PLC configuration ............................................................................................................................... 1

Operating Requirements ........................................................................................................................... 2

Steady State Operation .................................................................................................................................3

Start Up Types ..............................................................................................................................................4

Operator Adjustments in Automatic .............................................................................................................5

Manual Operation .........................................................................................................................................5

Change Over .................................................................................................................................................5

Exception handling / Alarming ...............................................................................................................6

Display Navigation .......................................................................................................................................8

Other Interface Requirements: .............................................................................................................. 11

Safety System Functions ................................................................................................................................ 12

Safety System Strategy ........................................................................................................................... 12

Safety System Hardware ......................................................................................................................... 13

Size System Management............................................................................................................................... 15

DownTime Tracking System (MES) ............................................................................................................. 16

Property of Procter & Gamble - Confidential

User Requirements Document

About this Document

Utilize Rockwell family of programmable logic controllers.

C&IS Software Standards

Property of Procter & Gamble - Confidential

User Requirements Document

1 LPD unit (late product differentiation unit)

1 fillers (Tech Long)

coding device (bottle printing, case printing, pallet labelling )

bottle weighing/reject system

Case packer (case erector, case sealer, case packer)

Case weigher/reject system

Palletising unit (stretch wrapper)

Airveyors for connecting the different machines

Simple block diagram

Property of Procter & Gamble - Confidential

User Requirements Document

Property of Procter & Gamble - Confidential

User Requirements Document

Property of Procter & Gamble - Confidential

User Requirements Document

Property of Procter & Gamble - Confidential

User Requirements Document

BOTTLE CAPACITY & DIM.

INTERNAL RSC SIZES

MAX PRODUCTION SPEED

Property of Procter & Gamble - Confidential

For the 1000ml bottle:

250 b.p.m. (21 cases/minute)

For the 2000ml bottle:

125 b.p.m. (21 cases/minute)

For the 750ml bottle:

250 b.p.m. (21 cases/minute)

For the 500ml bottle:

300 b.p.m. (25 cases/minute)

For the 1500ml bottle:

175 b.p.m. (29 cases/minute)