TRAINING PRESENTATION

TRAINING MODULE

UNIBLOCK
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Training Module

Project analysis slide 2 

Primary responsibility of a Uniblock Operator in
the bottling industry centers around efficiently
managing the machine to ensure smooth, safe, and
high-quality production.

 Breakdown of the key duties:

• Operating the Uniblock Machine Efficiently.

Uniblock • Ensure the continuous flow of bottles.
• Adjust machine parameters as needed.
• Inspect bottles for correct fill levels, secure
capping, and cleanliness.
• Minimize downtime and maintains air and water
pressure in the machines .
• Performing Routine and Preventive Maintenance
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Training Module I – Introduction to Uniblock Equipment

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Objective : Familiarize operators with the components, functionality, and role of the Uniblock
machine in the bottling

process.
1.1 Overview of Uniblock System:
•Rinsing Unit:
- Cleans the bottles before filling to remove dust, articles, or any other contaminants.
- Bottles pass through a rinsing station, where they are cleaned using a rinse or sterile
solution, often followed by a drying process.
- Components:
a) Rinsing Head
b) Rotary Table or Star Wheel
c) Solution Nozzles
d) Drain and Collection System

• Filling Unit:
- Common filling techniques include gravity filling, vacuum filling, or pressure filling.
- Controls the precise amount of liquid that is dispensed into each bottle.
- Components:
a) Filling Nozzle
b) Product Feed Tank
c) Flow Control Valves
d) Filling Mechanism
e) Sensors
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Training Module I – Introduction to Uniblock Equipment

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• Capping Unit:
- Seals the bottle with a cap after filling.
- The capping system often includes mechanisms for aligning, placing, and securing caps to
ensure an airtight seal.
- Components:
a) Cap feeder
b) Cap Sorter and Orienter
c) Capping Heads
d) Torque Adjusters
e) Cap Inspection Sensors

• Conveyor System:
-Transport bottles into and out of the Uniblock machine.
- Components:
a) Feed and Outfeed Conveyors
b) Guiding Rails
c) Transfer Star Wheels
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Training Module I – Introduction to Uniblock Equipment

Project analysis slide• Control

2 Panel and Interface:
- Touchscreen panel or display where operators set machine
parameters, monitor performance, and respond to alerts.
- Components:
a) Control Interface (HMI)
b) Programmable Logic Controller (PLC)
c) Sensors and Alarms

• Safety and Hygiene Components :

a) Emergency Stop Buttons
b) Safety Guards
c) CIP (Clean-In-Place) System

• Auxiliary Components:
a) Air Compressors:
b) Lubrication System
c) Vacuum System
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Training Module I – Introduction to Uniblock Equipment
 I.2 Process Flow: Rinsing Unit
3 4
1 2

Bottle Inverting Pre-Rinse or Initial Air Blast

Bottle Loading Bottles are rotated upside High-pressure air jets are
Bottles are fed into the Orientation Check
Sensors verify that each down to facilitate effective directed into the inverted
rinsing machine via a rinsing and drainage. bottle to remove loose
conveyor system. bottle is positioned correctly
particles or dust.
5

Primary Rinse
Nozzles spray high-pressure
water (often filtered or sterilize
zd) or a cleaning solution or sterile
rinse into the bottles to ensure
all surfaces are rinsed.

Draining
10 9 7 Bottles are held in the
8
inverted position to allow
Bottle Unloading Air Blowers / thorough drainage of
Cleaned bottles Inspection & Quality Control Vacuum Heaters Bottle Up righting the rinse water.
exit the rinsing machine and Bottles pass through an Bottles pass through
aligned to the conveyor inspection system an air blower or heater Bottles are rotated upright,
for seamless transition to to check for section to remove excess ready for drying or filling
the filling machine. residual contaminants moisture.
or moisture.
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Training Module I – Introduction to Uniblock Equipment
 I.2 Process Flow: Filling Unit
3 4
1 2
Bottle Positioning
Bottles are securely held Filling Valve Activation
Bottle Loading Alignment Check in place using clamps Once bottles are in position,
Bottles are fed into the Sensors verify proper and check whether the filling valves or nozzles
filler machine via a orientation to prevent each bottle is correctly lower into each bottle
conveyor system. spills or filling errors positioned to start filling
5

Volume Control
Machine dispenses a
Predetermined volume into
each bottle monitored by
flow meters or sensors.

9 8 7
6

Bottle Disengagement Bottle Up righting

Bottles are released Filling Valve Retraction
A secondary check
from stabilizers and The filling nozzles retract Bottle levelling
ensures all bottles are
prepared for transfer from each bottle once Excess liquid is captured and
filled precisely and any
to the next station. the correct amount either recirculated or drained,
irregularities are flagged.
is dispensed
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Training Module I – Introduction to Uniblock Equipment
 I.2 Process Flow: Capping/ Sealer Unit
3 4
1 2
Cap Placement
Sensor Check Bottles are securely held
Cap Sorting & Feeding in place using clamps
Capping Station Cap feeder or elevator sorts Sensors may verify cap
Filled bottle reaches orientation and placement, and check whether
And feeds caps into each bottle is correctly
to capping station the machine. rejecting improperly
positioned positioned
5
caps
Capping Process
The capping head descends
, applying pressure and
rotating the cap to seal
it onto the bottle neck.

9 8 7
6
Bottle Outfeed Cap Presence Detection Torque and Seal
Check Sealing & Tightening
Sensors measure the A secondary check
After capping, bottles are Sensors to confirm that
torque applied
. to each ensures all bottles are
released from stabilizers Each bottle has a cap and
cap, ensuring it is within filled precisely and any
and transferred to labelling that it properly seated
specified limits. irregularities are flagged
and packaging section. and sealed.
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Training Module II – Machine Set Up & Operations

Project
production.

analysis slide 5
Objective : Equip operators with the skills to efficiently operate the Uniblock machine during bottling
2.1 Pre Start : Set Up
1. Inspect machine components for cleanliness, wear, or damage.
2. Checking all sensors, conveyor belts, and other moving parts.
3. Ensure all raw materials (bottles, caps, liquid) are ready for production.
4. Check power supply .
5. Ensure proper alignment of moulds.

 2.2 Machine Start Up:

1. Step-by-step guide on powering up the Uniblock machine.
2. Navigating the control panel: machine interface basics, setting parameters (e.g., fill levels, speeds).
3. Calibration of sensors and detection systems.
4. Ensure proper height is adjusted as per specifications.
5. Ensure that the correct pipeline connections are made, and the unused pipelines
shall be covered with blind flanges or nipples.
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Training Module II – Machine Set Up & Operations

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 2.3 Operating Procedures
1. Load material or product into the system
2. Start and stop the machine
3. Adjust machine settings (speed, pressure, mold settings)
4. Monitoring the production process
5. Handling batch changes or material types
6. Identifying and addressing common issues such as:
- Bottle misalignment.
- Improper filling levels.
- Cap misplacement.

 2.4 Shut Down Operations:

1. Checks the Lubrication level and manual Point for lubrication as per CLITA .
2. Disconnect the air connection valves and other associated connections
3. Drain out by opening the draining valve to the blend holding tank
4. Check the condition of filter and nozzles and the level of liquor in the filling tank/constant level tank
5. Ensure no bottles are present in the conveyor or Uniblock Machine.
6. Condition of washer, nozzle and filter should be checked and clean properly
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Training Module II – Machine Set Up & Operations

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 2.5 Product Changeovers
1. How to perform changeovers for different bottle sizes or product types.
2. Adjusting machine settings, replacing tooling or nozzles as needed.
3. Cleaning and sanitizing the machine during product changeovers .
4. Remove the Worm Wheel Timing Screw /Star Wheel.
5. Remove the disc and the cap Chute also as per the different cap sizes.
 2.6 Hands- on Practice
1. Operators should undergo practical training under supervision
2. Practice different operational modes
3. Real-Time Monitoring and Adjustments
4. Bottle Handling and Conveyor Operation
5. How to identify worn or damaged components, and when to alert the maintenance team.
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Training Module III – Safety Protocols

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Objective : To ensure the well-being of employees, maintaining product quality, and complying with
industry regulations
 3.1 General Safety Guidelines
1. Always wear Personal Protective Equipment (PPE): gloves, ear protection, safety glasses, etc.
2. Familiarization with emergency stops and shutdown procedures.
3. Lockout/ Tagout (LOTO) procedures for maintenance.
4. Importance of proper machine guarding to prevent injury.

 3.2 Emergency Response

1. Actions to take in case of machine malfunction or emergency.
2. Use of emergency shutdown procedures.
3. Reporting accidents or unsafe conditions.
4. First Aid for electrical shock,burns, or physical injuries

 3.3 Uniblock-Specific Safety Protocols

1. Safety interlocks and machine guarding systems.

2. Safe handling of caustic or cleaning agents used in the rinsing unit.
3. Hazards related to high-pressure filling systems.
4. Proper procedures for clearing jams or bottle/cap misfeeds.
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Training Module IV – Maintenance & Troubleshooting

Project analysis
Objective : Train operators on the slide 5
preventive maintenance tasks and cleaning procedures required
to keep the machine running smoothly and in compliance with safety and hygiene standards.

 4.1 Daily Preventive Maintenance

1. Lubricating and greasing key machine parts (bearings, conveyors).
2. Check wear parts (seals, belts, and nozzles) and replacing if necessary.
3. Inspect sensors and electronic components for dust, debris, or damage.
4. Check for play , bent & tighten for motor and gearbox of Infeed Conveyor and Height adjustment

 4.2 Cleaning Procedures

1. Cleaning the rinsing, filling, and capping stations.
2. Sanitizing contact parts to meet hygiene standards
(especially in food and beverage industries).
3. Clean filters, pumps, and hoses to prevent clogging or contamination.
4. Drain all the form of wastes
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Training Module IV – Maintenance & Troubleshooting

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 4.3 Planned Maintenance
slide 5
1. Participate in scheduled maintenance tasks alongside the maintenance team.
2. Documenting machine performance and maintenance activities in logs.
3. Check for leakage, blockage and condition of rinser ,filler, capper.
4. Prepare maintenance plan for the machine
5. Tools should be easily accessible which are required to maintain uniblock machine.

 4.4 Troubleshooting Common Issues

1. Identify the most common issues (eg: system jams, low pressure, eratic vibrations)
2. Steps for troubleshooting (checking power supply ,inspecting machine components, recalibrating)
3. Diagnosing hydraulic problems
4. Handling sensor malfunctions or alignment issues.
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Training Module V – Quality Control and Performance Monitoring

Project analysis
Objective: Ensure slide
operators understand 5 and monitor product quality
how to maintain
throughout production.
 5.1 Key Quality Parameters
1. Correct bottle fill levels.
2. Proper cap application (securely fitted without damage).
3. Bottle and product cleanliness (no contaminants or leaks).

 5.2 Product Quality Standards

1. Understanding acceptable product tolerance(size, weight, shape)
2. Adjusting machine settings for consistent product quality
3. Identifying defects and ensuring consistent quality output
4. Importance of regular sampling and inspection
5. Spot-checking bottles during production for defects.

 5.3 Monitoring System Performance

1. Key performance indicators (KPIs) for machine efficiency.
2. Tracking downtime, cycle times and output rates
3. Using the control panel to monitor machine health
4. Reporting issues to supervisors or maintenance team
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Training Module VI – Documentation & Reporting

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Objective: Ensure slide
operators understand 5
the importance of record keeping.

6.1 Machine Operation Logs

1. Keep track of production output and downtime.
2. Recording machine settings and any adjustments made.
3. Noting any issues or maintenance performed during shifts.
4. Maintaining machine ledger and checklist

6.2 Reporting Issues

5. How to report malfunction ,production anomalies, or safety concerns
6. Proper documentation format and escalation process.
7. Maintain appropriate records for the Cleaning and Sanitation as mentioned in this document:
• Line CIP record.
• Cartridge filter change record.
• Pressure monitoring.
• Shift End report.
• Hygiene report.
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Training Module VII – Continuous Improvement and Best Practices

Project analysis
Objective: Encourage
operation.
operators toslide 5
contribute to the ongoing improvement of the Uniblock

7.1 Efficiency Improvement

1. Identifying opportunities to reduce machine downtime or product changeover times.
2. Optimizing machine speeds without compromising product quality.

7.2 Collaborating with Maintenance and Quality Control

3. Working as a team to identify root causes of recurring issues.
4. Proposing improvements to SOPs or machine settings based on experience.

7.3 Staying Up-To-Date

5. Participating in advanced training sessions or refresher courses as new technologies or updates are introduced.
 Training Module

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Tools required for Uniblock Machine ( Operation , Maintenance & Quality )

Allen key set ( 1.5 to 10 mm ) T-shaped Allen key set ( 1.5 to 10 mm ) ) Straight Nose pliers ) Bend nose pliers Universal pliers Screw driver Cross / Ball pien hammer

Tester Adjustable spanner One end Open and ring Spanner set Oil can Grease gun Measuring tape Mallet hammer

Lux Meter Micro Screwdriver Screw driver Tool

Digital Multimeter Hex Tubular Box Rachet Spanner Set Label Gauge
Tool kit kit 65 pieces
Spanner Set (8-19 (8-19 mm)
mm)
 Maintenance Plan

Project analysis slide 5 Fitter Check the condition of Filter , replace if found black and choked
 Quarterly

Check the condition of regulatory part , if found leakage , replace the  Quarterly
Regulator same
FRL Unit

Lubrication Drain and check the oil level  Quarterly

Unit

Check the condition & clean Water tank , Filter Cartridge ( Replace if  Weekly
Water Tank required)
Check for condition , leakage and blockage of water to rinser Unit  Monthly
Check the condition of High and low level Sensor Condition
 Monthly

Drain Waste & check the oil level.  Weekly

Lubrication Strobe (LED)
Condition of Lubrication carrying Pipes and Ferrule Connectors (Grease  Quartely
Nipples), check for any Leakage

Check the water jet condition & pressure. If found block, replace immediately , Jet
Water Tank  Weekly
spraying nozzles (water & air)
Check for bend and deformation, replace if required (Nozzle assembly); Check the
Infeed condition and tighten ( Guide strips , water Pipes ); Check the surface for wear
and deformation, and repair/ replace if required (Star wheel & guides , Wheel  Monthly
Rinser Shaft , Worm Shaft Bearings),
Complete
Check for play & tighten for motor and gearbox of Infeed Conveyor and Height
Rinser Unit
Water adjustment ; Check the water jet height at each plunger nozzle ; Clean &
Grease/Lubricate  Quarterly
Distribution Check For Plays And Tighten; Check for condition, leakage, and blockage. (replace if required); Clean
system and replace/tighten, if required. Bottle Gripper Unit; Check the condition for any damaged or broke  Quarterly
part (replace, if required); Check for rusting and replace parts
 Note : Hours, Months & Years depicted are frequency of maintenance and it also represents responsibility related to it.
 Maintenance Plan

Project analysis slide 5 Filler Infeed

Check the condition & clean (replace if required); Check the Nozzle alignment and
condition. If found block, replace immediately.
 Weekly

Ensure that the cam rollers are following the cam track correctly; Check the
Lifter condition and tighten
Assembly  Monthly
Filler Clean Panel Box & Wires; Check the surface for wear and deformation, and repair/
Product
Tank replace if required;
Check for condition, leakage, and blockage. (replace if required) ;  Quarterly
Filliing Nozzle Check the condition for any damaged or broke part (replace, if required) and
 Annually
replace parts if required

Ensure that the cam rollers are following the cam track correctly; Lubricate Height
Capper Unit  Weekly
Adjusting Shaft

Capper Check the condition and alignmemt of Cap Chute and Cleaning jett; Check for play
Chute & tighten  Monthly
Rinser Capper
Hopper
Clean & Grease/Lubricate / tighten
 Quarterly
Cap Cleaning
Check the condition for any damaged or broke part (replace, if required)  Quarterly

Outfeed Lubricate & Grease  Chain sprocket & chain ,  Condition of change parts ,
 Annually
Conveyor Capper heads

 Note : Hours, Months & Years depicted are frequency of maintenance and it also represents responsibility related to it.
Thank You