WRAP has prompted the British glass industry to produce a new lightweight glass bottle for liquids such as wine and coffee. However, existing manufacturing, bottling, transportation, etc. processes are designed for traditional heavier, more solid glass containers, and this new, sustainable design is not applicable. Light glass, whether empty or full, increases the risk of glass breakage at container manufacturers, beverage bottling plants, and delivery trucks. The UK's non-profit organization Waste and Resource Action Plan (WRAP) has launched a project to encourage glass bottle manufacturers and food and beverage companies to use lightweight glass containers to reduce the fuel consumption of glass waste and glass products transportation.
In order to identify the fragile sites of glass in the bottling plant and improve the production line efficiency and quality control in the bottle making process, Irish glass manufacturer Ardagh Glass adopted the RFID-based Agent QC system provided by Sensor Wireless. By locating excessive pressure and the source of collision problems between the bottle and the machine or other bottle, Ardagh can reduce the cost of product damage and mitigate the problem of landfill debris from broken glass.
The Agent QC system includes a smart bottle - a replica of an actual glass bottle with an embedded RFID tag on the sensor. By placing the smart bottle in the assembly line, the company can identify the exact location where the glass container will be damaged, according to Waywire McNally, president of Sensor Wireless.
Smart glass bottle with embedded RFID tag on sensor
The system also includes a hand-held RFID reader for capturing data from smart bottles on the production line, and data compilation software. In addition, the Agent QC system was also used by beverage companies including Coors, E. & J. Gallo Winery, Coca-Cola and Kirin Beer to track the machine's pressure on the bottle when capped.
Ardagh Glass is the world's largest glass manufacturer, producing 12 billion glass bottles each year. There are 20 manufacturing plants in Europe and 6,500 employees. Ardagh Glass has added lightweight glass to the company's products. Paul O'Neill, senior customer service manager for food, milk and beverages, said that the company is using the Agent QC system to track the manufacturing process of four new bottles, O'Neill Rejected to disclose the name of the customer who ordered the new bottle.
When Ardagh received a new bottle order, the company sent the specifications of the bottle to Sensor Wireless, and engineers used acrylic plastic to replicate the same smart bottle. The bottle contains a 3-inch RFID tag and sensor, which is circulated in the Ardagh Glass factory along with other bottles. The smart bottle sensor measures pressure, shock and temperature. The sensor is connected to a battery-charging RFID tag that can transmit data at 900 MHz using a proprietary air interface protocol or 2.4 GHz in compliance with the ZigBee standard.
Using ZigBee technology can send a large amount of data, McNally said, but the 900 MHz signal will be more stable. When smart bottles flow through the assembly line, employees place or hold readers at important locations, such as manufacturing lines, or transport products to warehouses. In these places, changes in the bottle's impact, pressure, or temperature can damage the glass bottle.
Employees can view smart bottle data on the screen of the Sensor Wireless handheld device, store the data in the handset, and later connect it to the computer via the USB interface and download the data to the Ardagh Glass ERP system. Ardagh uses Sensor Wireless's other software to analyze the production line and test whether any modifications on the production line can improve process efficiency.
According to McNally, Ardagh Glass has used Agent QC in several factories and produced new bottles for 4 customers in the past 2 years; the adoption of Agent QC improves the manufacturing process, limits bottle damage, and identifies problem points. .
By the end of 2009, McNally said that Sensor Wireless will add GPS capabilities to its smart bottle system, and the in-bottle label will send sensed data via a satellite antenna mounted on a transport truck. This will allow the user to understand where the accident occurred during shipping (such as strong bumps and vibrations).
In addition, Sensor Wireless is also developing an automated system that allows data to be automatically transmitted to 900 MHz RFID readers or ZigBee nodes on-site without any human intervention. This requires the installation of low-cost readers or nodes on the assembly line. McNally claims that he is still looking for a suitable product. Most readers are still too large and consume too much power.
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