Interview with Mr. Tanaka, Technical Director of Sakura Shampoo, at Tengzhuo Packing Machinery

Interviewer: Mr. Tanaka, thank you for visiting Tengzhuo Packing Machinery today. We understand Sakura Shampoo is looking to upgrade its filling production line. Could you tell us a bit about your current challenges and what you hope to achieve with a new system?

Mr. Tanaka: Thank you for having me. At Sakura Shampoo, we've seen significant growth, and our existing filling line is struggling to keep up with demand. We face several issues:

Slow Changeover Times: We produce a range of shampoo and conditioner types in various bottle sizes. Switching between these formats is time-consuming, leading to significant downtime.

Inconsistent Filling Accuracy: We've experienced some issues with fill level accuracy, resulting in product wastage and potential customer dissatisfaction.

Limited Automation: Our current line requires a fair amount of manual intervention, increasing labor costs and the risk of human error.

Integration with Existing Systems: We need a new line that can seamlessly integrate with our upstream (mixing) and downstream (capping, labeling) equipment.

Future Scalability: We anticipate further growth and need a solution that can accommodate increased production volumes in the future.

Interviewer: Those are common challenges in the industry. At Tengzhuo, we focus on providing solutions that address these specific pain points. Could you elaborate on the range of bottle formats and the desired output you're aiming for?

Mr. Tanaka: We currently handle PET bottles ranging from 200ml to 750ml, with plans to potentially introduce a 1-liter option. We also have a few specialized bottle shapes that can be challenging to handle. Our current output is around 40 bottles per minute, and we're aiming to increase this to at least 80-100 bottles per minute with the new line.

Interviewer: Based on your needs, we believe our TZ-FL Series High-Speed Multi-Format Filling Line could be an excellent fit. This line is designed with rapid format changeovers in mind. Could you tell us what aspects of changeover speed are most critical for Sakura Shampoo?

Mr. Tanaka: The downtime associated with changeovers is a major concern. We need a system that allows us to switch between bottle sizes and product types quickly and efficiently, ideally in under 30 minutes. Features like tool-less adjustments and pre-programmable settings would be highly valuable.

Interviewer: Our TZ-FL series incorporates precisely those features. It utilizes quick-release mechanisms for change parts and a user-friendly touchscreen interface where operators can recall saved settings for different bottle formats. Servo-driven adjustments further automate the process, ensuring accuracy and reducing manual intervention.

(At this point, the interviewer would likely show Mr. Tanaka a demonstration or video of the machine in operation, highlighting the changeover process.)

Interviewer: Regarding filling accuracy, our system utilizes servo-controlled piston pumps  which offer high precision and consistency. We can customize the filling heads and nozzles to suit the viscosity of your shampoo and conditioner products, minimizing dripping and ensuring accurate fill levels across all bottle sizes.

Mr. Tanaka: Inconsistent filling has led to product giveaway, which impacts our bottom line. The precision you describe sounds promising. What about the integration with our existing capping and labeling machines?

Interviewer: Our filling lines are designed for seamless integration with other packaging equipment. We can provide synchronized conveying systems and communication protocols to ensure a smooth flow of bottles from filling to capping and labeling. We would need to understand the specifications of your existing machines to guarantee compatibility.

Mr. Tanaka: That's important. We also need to consider future scalability. Is the TZ-FL series easily expandable if our production volumes increase further?

Interviewer: Absolutely. The modular design of the TZ-FL series allows for future expansion. You can add more filling heads or upgrade the conveyor system to accommodate higher output rates as your business grows. This provides a level of future-proofing for your investment.

Mr. Tanaka: This all sounds very impressive. However, we did experience a significant issue with our previous filling machine: occasional foaming with one of our thicker shampoo formulations. How does your system address potential foaming problems?

Interviewer: That's a valid concern, especially with viscous liquids. Our TZ-FL series can be equipped with several features to minimize foaming:

Submerged Nozzles: For certain products, we can implement filling nozzles that descend into the bottle during filling, reducing the drop height and minimizing aeration.

Slow-Start and Slow-Stop Filling: The servo-controlled filling process allows for gentle acceleration and deceleration of the filling process, reducing turbulence and foam generation.

Anti-Foaming Filling Heads: We can incorporate specialized filling head designs with features like anti-drip and anti-foam mechanisms.

Nitrogen Purging: For highly sensitive products, we can integrate a nitrogen purging system to displace oxygen and further reduce foaming.

Mr. Tanaka: The submerged nozzles and slow-start/stop features sound particularly relevant to our thicker formulations.

Interviewer: To further understand your specific foaming issue, could you provide us with the viscosity range of your products? We can then tailor the filling head design and parameters to optimize the filling process and minimize foaming.

(Mr. Tanaka provides the viscosity information.)

Interviewer: Based on this, we recommend [suggest a specific nozzle type and filling parameter adjustments, e.g., using bottom-up filling with a specific nozzle design and a controlled filling speed profile for the thicker shampoo]. We can also conduct a product trial at our facility using your shampoo to fine-tune the settings and ensure optimal performance before you make a final decision.

Mr. Tanaka: A product trial would be very beneficial and would give us greater confidence in the system.

Interviewer: We'd be happy to arrange that for you. We are confident that the TZ-FL series can significantly improve your filling production line, addressing your concerns about changeover times, filling accuracy, automation, integration, and scalability. By implementing the recommended anti-foaming measures and conducting a product trial, we can also ensure smooth and efficient filling of all your shampoo formulations.

Mr. Tanaka: This has been a very informative discussion. The features you've described seem to align well with our needs. The focus on rapid changeovers and filling accuracy is particularly appealing. Thank you for taking the time to understand our challenges and propose potential solutions.

Interviewer: Thank you for visiting us, Mr. Tanaka. We look forward to the possibility of partnering with Sakura Shampoo and helping you optimize your filling production. We will be in touch shortly to schedule the product trial.