Know the bottle family
Group bottle formats by diameter, height, base shape and stability. Similar bottles may still need different guide settings.
Changeover
Bottle unscrambler changeover guide
Changeover planning matters when a line runs more than one bottle size or shape.
Specification advice
What this means for the bottle infeed section.
Document settings
Keep clear settings for guides, rails, speeds and any change parts so the next production run starts cleanly.
Test the extremes
The smallest, tallest, lightest or least stable bottle is often the format that decides the machine route.
Practical checks
Use the bottle and line data to reduce quote guesswork.
The best enquiry includes real bottle information, the target line speed and details of the downstream equipment. This gives the supplier enough information to recommend a sensible machine route instead of guessing from a catalogue picture.
For urgent projects, send bottle photos, sample dimensions, output target, conveyor height and a short description of the current line problem.
Format rangeall current and planned bottles
Adjustmenttool-less or set-point based where practical
Operatorsclear setup instructions
Testingcheck the worst-case bottle
Questions
Common questions before choosing a bottle infeed route.
Can one machine feed different bottles?
Often yes, but the bottle range must be checked before specification.
What makes changeover slow?
Unclear settings, poor access, unstable bottle formats and unplanned change parts can all increase time.
Should future bottles be considered?
Yes. Future formats can affect the best machine route and layout.
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Changeover acceptance
Define the bottle family, settings and evidence before production handover.
Changeover should be treated as an operating process. The setup needs identifiable parts, recorded settings and a check that proves the bottle is stable before full production resumes.
| Changeover item | Record | Acceptance evidence |
|---|---|---|
| Bottle family | Smallest, largest, lightest and least stable formats. | Each governing format runs through the complete infeed route. |
| Adjustable settings | Guide positions, outfeed gaps, speed settings and sensor positions. | Settings are repeatable and linked to the bottle format. |
| Dedicated change parts | Part identity, storage location, installation sequence and inspection. | Correct parts can be selected and fitted without ambiguity. |
| Operator access | Tools, guarding, safe access and lifting/handling needs. | Changeover can be performed safely using the agreed method. |
| Restart check | Initial bottle sequence, stable flow, outfeed presentation and downstream transfer. | The line reaches normal operation without repeated manual correction. |
Operator evidence
Use a settings sheet and short changeover video together.
The settings sheet controls dimensions and part identity. A short video records the practical sequence, access points and the first bottles used to verify the setup. Keep the video tied to the machine model and bottle code so it remains useful after staff changes.
Bottle code and sample photograph
Guide, rail and outfeed settings
Change-part identification
Tools and safety access
First-bottle verification sequence
Normal-run confirmation after restart
Change-part verification
Link every bottle family to the correct parts, settings and first-bottle checks.
A changeover record should allow a trained operator to repeat the setup without relying on memory. It should also show which bottle extremes were used to prove the machine envelope.
| Record | Minimum content | Verification |
|---|---|---|
| Bottle-family ID | Dimensions, material, weight, photos and representative sample reference. | Match the physical bottle to the approved schedule before adjustment begins. |
| Parts and guides | Part ID, guide position, orientation element and any dedicated tooling. | Visual check that the correct parts are installed and secured. |
| Machine settings | Relevant speed/adjustment references and outfeed guide positions. | First-bottle and low-speed check before normal operation. |
| Acceptance checks | Stability, orientation, surface condition, transfer, stop and restart. | Short unedited video and signed settings record. |
| Operator handover | Change sequence, safe access, tools, removed parts and final production state. | Repeat changeover by the operating team using the record only. |
Keep the orientation video with the settings sheet and use the damage trial where bottle appearance changes between guide setups.