PET preform and bottle
When bottles are blow-moulded from PET preform, IoT counts incoming preforms and finished PET bottles in real time. Output volumes, utilisation and jams at the machine outlet become visible, even on machines without a digital interface.
PET preform and bottle at a glance
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PET preform and bottle: count units and detect jams in real time
In the solution example, the ZentNodeCT IoT adapter records directly at the blow moulder the number of incoming PET preforms, the finished bottles and level signals at the outlet that indicate a jam. It calculates maximum, minimum and average values at user-defined intervals and sends them via MQTT. The ZentNodeIO adapter reads 24 V signals from material level detectors, signal lights and status indicators. A ZentEdge server writes everything to an SQL database that is connected directly to the MES. Single Pair Ethernet carries data at 100 Mbps and power over a single cable, encrypted with TLS.
The user is a multinational soft drinks manufacturer from the consumer goods sector. Its new PET blow moulder, which forms bottles from heated preforms under pressure, had a proprietary control system and no interface to the MES. Perinet and development partner Zentinel solved this with a retrofit that does not touch the controller. The solution also records energy consumption, utilisation and cycle times. According to the source, the system was ready for use immediately and makes comparisons between shifts or plants easier, because output volumes and faults are available in real time.
PET preform and bottle: frequently asked questions
Which data does IoT capture on a PET bottle production line?
On a PET bottle production line, IoT mainly captures unit counts, jams, energy consumption, utilisation and cycle times. In the Perinet example, the ZentNodeCT adapter counts incoming preforms and finished bottles and detects a jam via level signals at the outlet. The ZentNodeIO adds signals from material level detectors, signal lights and status indicators. All data reaches the MES via an edge server.
Can a stretch blow moulding machine without an interface be connected to the MES?
Yes, a blow moulding machine without a digital interface can be connected to the MES by retrofit. Perinet and Zentinel use external IoT adapters that pick up signals directly at the machine without interfering with the proprietary controller. An edge server collects the data in an SQL database connected to the MES. No modification of the machine is required.
How are jams between preform feed and bottle outlet detected?
Jams are detected via level signals at the machine outlet and by comparing incoming preforms with finished bottles. The ZentNodeCT adapter records both directly at the blow moulder and calculates maximum, minimum and average values at user-defined intervals. The values are sent via MQTT to downstream systems, so output volumes and potential faults are available in real time.
How much cabling does data capture on PET preforms and bottles require?
Cabling stays minimal because Single Pair Ethernet carries data and power over a single cable. In the Perinet example, SPE connects the IoT adapters and the edge server at 100 Mbps and makes complex gateways unnecessary. Devices can be integrated into IT networks via standard protocols such as HTTPS, MQTT or a REST API, and all transmission is encrypted with TLS.
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