Gerolsteiner Brunnen is bottling since 1888 and is the best-known german mineral water brand. In 2024, 8 million hectoliters were bottled in the Vulkaneifel region in the Western part of Germany. The photo above shows how the palletizer for a certain bottling line is fed with six-packs of 1.5-liter PET bottles by four-lanes. The previous system with stopper systems created repeated product jams and line downtime in the pallet layer preparation. Our job was to optimize the palletizer with continuous and trouble free feeding of the palletizer table, minimizing intervention by the staff, while making it simpler in case it happens.
Sophisticated controlled production flow to the palletising table
Four Sortec carton and pack rotation systems were installed ahead of the two palletizing tables, each with conveyor belts tailored to the product flow, and the belt speeds guided by the requirements of the palletizer. The products are sometimes rotated 90 degrees by our rotary systems, and sometimes they run lengthwise through the station for the required layer patterns. Depending on the needs, the shrink packs are fed either to the 1200 × 800 mm Euro pallet or the half-size 800 × 600 mm CHEP pallet.
The two existing flow diverters for separating the products into columns of five or six from single-lane to dual-lane transport were kept for budgetary reasons, as was the palletizer with its programmable logic controller (PLC).
Production flow was increased by feeding the palletizer more continuously than previously possible thanks to our optimized belt control.
The products arrive at the palletising table from the turning station via a user-friendly distance.
Operational delays and stops were significantly reduced because the products come to the palletizing table from the turning station with virtually no jams and without twisting.
How the palletizers were optimized
We replaced the existing conveyors with a total of 12 new belts: dosing belts, stopper belts and flat-top conveyor systems made of plastic mat chains for smooth rotation of the shrink packs below our turning stations. First, the packs coming from the handle applying machine are distributed from the single-lane to the two-lane conveyor by the existing flow diverter so that the packs come parallel on 2 + 2 belts. The speed control of the aforementioned stopper and dosing belts then takes over the transport flow. Finally, the layer image is created by aligning the shrink packs through our 90 degree turning station.
View of two of four lanes. Products with sensitive films are passing through lengthwise or rotated 90° by our rotation system gripping them from above – Photo Sortec Sorting Technology
Smooth running palletizer thanks to optimized belt control
The product speed between the flow diverter and the turning station is controlled for gaps and congestion. Based on this information, the belt speed is quickly adjusted to ensure that there are always enough products available on the palletizing table. To achieve this, we adapted the palletizer’s existing older PLC control system.
As the video shows, our rotary tunnel systems turn the packs faster than was previously possible. Your closer look reveals that the packs leave the turning station on the conveyor belt in the centre, regardless of whether they have been turned or not. The products arrive at the palletizing table in the intended amount and order.
Smoother palletizer operation
Our belt control system optimizes the existing palletizer and increases the performance of the entire line. The palletizer runs more economically operating continuously without stop-and-go or time-consuming restarts. The new belt control system further extends the service life of the existing, costly palletizer.
To further speed up the production process, we recommend distributing the packs more evenly across two or four lanes using one of our → distribution systems. Here we offer a proven, significantly faster solution that runs with less wear and tear and can be adjusted quicker.
Sortec is specialized for many years with proven distribution and turning systems with corresponding dosing, stopper and turning belts. Sortec offers
a proven and functional solution
planning the new setup of conveyor belts
operation with the existing software
installation and commissioning of the system
training of your staff
As a user, you get a cost-effective solution from a single supplier with one reliable contact person, from planning to commissioning at your plant.
We are proud that we were able to solve this challenging task within the given space constraints and other cost specifications in autumn 2025 with our many years of expertise. The result is a significant performance increase for this 1.5 litre PET mineral water bottle line.
