Earthbound Automation developed a custom cup rejection solution for a food packaging application, connecting inspection signals with product tracking and pneumatic rejection. The project scope covered mechanical and electrical design, fabrication, PLC programming, installation, and commissioning.
The Challenge
Detecting a rejected cup is only part of the process. The system also needs to track that cup through the machine and remove it at the correct location.
This application required a solution that fit the existing equipment and product handling arrangement. Filled cups traveled along guide rails supported by their rims, creating specific constraints for the reject mechanism’s placement, stroke, and contact with the product.
The controls also needed to account for an indexing sequence that advanced two cups per machine cycle.
Our Solution
A Reject Mechanism Built Around the Product
We designed a pneumatic reject mechanism around the existing cup path. A custom pusher provided the contact geometry needed to move a selected cup out of the product stream.
The design considered cup weight, rail geometry, available space, and actuator travel to create a solution tailored to the machine.
Product Tracking Through Each Index
The PLC logic associated incoming reject signals with individual cup positions and advanced those decisions with the machine’s indexing sequence.
With two cups advancing per index and six indexes between inspection and rejection, the tracking sequence accounted for 12 product positions. This connected the inspection decision to the cup’s downstream location.
Inspection and Machine Integration
The system received reject requests from third-party inspection equipment. Earthbound’s controls handled the tracking and actuation needed to turn those requests into physical rejection.
Local photoeyes provided cup detection near the reject mechanism, supporting the timing between product arrival and cylinder actuation.
Project Scope
Mechanical design of the reject mechanism and mounting arrangement.
Electrical design and integration of sensors and pneumatic controls.
Fabrication of custom reject components.
PLC programming for reject tracking and actuator sequencing.
Integration with third-party inspection signals.
Installation and commissioning within the existing production equipment.
Project Highlights
Existing equipment integration
A custom reject solution designed around the cup sealing machine’s layout and operating sequence.
Individual cup tracking
Position-based logic that accounted for two cups moving during each machine index.
Coordinated mechanical and controls design
Product handling, sensing, and PLC sequencing developed together.
From inspection signal to physical rejection
Integration of external reject decisions with the machinery required to remove the selected cup.
