Suitable for
Projects that match this page decision
- Several PET bottle formats using a compatible handling concept
- Plants that can freeze drawings before design approval
- Buyers willing to define a repeatable changeover procedure
Format management / more than one SKU
PET Bottle Changeover: Parts and First-Off Checks
A second bottle format needs more than a stored recipe. Confirm which physical parts and settings change, how the first bottles will be approved and what the quoted changeover time includes.
Answer first
Only after reviewing both bottle/cap formats and confirming parts, settings and trials. Specify output for each format separately; a 500 ml catalog rating does not approve 1.5 L performance.
Make each bottle-format transition repeatable
Freeze the format and parts list
Give every bottle and cap a drawing revision. Compare neck/support ring, height, diameter and shape. Ask the supplier to identify common settings, adjustable guides and dedicated transfer or cap-feed parts for each format.
Separate recipe and physical conversion
A selected recipe does not verify installed parts or guide positions. Request a parts/settings checklist, identification and storage plan. Trained personnel must follow the supplied stopping, isolation and changeover instructions.
Approve the first-off result
After the approved conversion, check bottle transfer, rinsing, fill result, cap placement and closure integrity using the new format's agreed conditions. Record startup rejects and approval before releasing normal production.
Define the timing evidence
State the starting and finishing events, personnel, tools and included checks. Last acceptable old-format bottle to accepted new-format production is one possible basis. Verify each required direction and record unresolved parts, training and trial needs.
Not suitable for
Boundaries that need a different platform or review
- Future bottles with unknown geometry
- Assuming all 500-2000 ml bottles need no parts
- Adding a second cap family without sorter and chute review
Inputs required
Evidence to provide before confirmation
- Dimensioned drawing and sample for every SKU
- Bottle neck and cap comparison matrix
- Expected production sequence and changeover frequency
- Available storage and identification for format parts
Machine function
What happens at this machine or decision boundary
- The review separates common machine settings from format-specific items.
- Guides, transfer points and cap handling are checked across the format envelope.
- The approved method becomes part of training, spares and FAT planning.
Configuration decisions
Options that must appear in the proposal
- Manual adjustment versus dedicated parts
- Reference format for rated output
- Format-part storage and identification
- FAT matrix and changeover timing method
Interface requirements
Upstream, downstream and utility handovers
- Upstream bottles must arrive in a stable orientation for every format.
- Outfeed and downstream equipment need matching guide ranges.
- Control recipes should correspond to physical settings and parts.
Buyer risks
Questions to close before order
- Undocumented settings that cannot be repeated by operators
- Star-wheel or guide interference with a new bottle shape
- Quoting one speed and applying it to every SKU
FAT checks
How to verify the agreed basis
- Complete at least one documented format change during FAT.
- Verify correct parts, settings and recipe identification.
- Run representative small and large formats at their agreed basis.
Quotation scope
What the commercial offer should state
- Named SKU list and revision status
- Included format parts and adjustment points
- Changeover tools, instructions and training
- FAT formats, duration and output basis
Questions to settle before requesting a quote
Can one water filler run 500 ml and 1.5 L bottles?
Only after reviewing both bottle/cap formats and confirming parts, settings and trials. Specify output for each format separately; a 500 ml catalog rating does not approve 1.5 L performance.
Does selecting a recipe complete bottle changeover?
No. Physical guides, transfer parts and cap handling may also change. The approved procedure must connect the recipe to the actual installed parts and inspected settings.
What should the changeover quotation include?
Named formats and revisions, supplied change parts, adjustment points, tools, instructions, training and trial coverage. Require a defined timing method rather than an unsupported universal changeover time.
Related decision
Selection Tools
Calculate preliminary required BPH from daily saleable bottles, net hours, planning efficiency and growth reserve, then compare an XGF reference band.
Allot Tech / bottle-size-changeover
Turn this decision into a comparable machine scope
Send the bottle, cap, reference output, existing equipment and destination. Final values are confirmed in the project proposal.
Mr Kcal
Allot Tech (Suzhou) Co., Ltd.