Icon Equipment – Case Study
Rebuilt ICON 5000 High-Speed Filler for Large Format Containers
Background
A customer approached ICON in search of a cost-effective solution for high-speed filling of large-format containers while staying within budget constraints. To meet this need, ICON provided a rebuilt machine that was inspected and refurbished to ensure it met stringent performance, safety, and quality standards.
This rebuild was a key component of a broader multi-stage project, where ICON not only restored the filler but also designed, manufactured, and supplied additional equipment to optimize the entire production line. The project included the installation of conveyors, a gripper conveyor, an inverter, line diverter, bottle rinser, and integrated control systems.
Filler Rebuild process
✅ Full Machine Disassembly & Restoration – The entire machine was stripped down, allowing for a thorough inspection and reconditioning of all components. The base was fully polished and refurbished, ensuring a clean, corrosion-resistant, and durable surface for long-term performance.
✅ Filler Operation – Critical components were inspected, recalibrated, and replaced to restore best performance:
- Bowl level control replaced and recalibrated to ensure consistent filling accuracy.
- Pipework, vent tubes, sleeves, rollers, and shafts were examined and replaced where necessary.
- Key wear components such as seals, bearings, springs, retainers, spacers, and O-rings were systematically replaced.
✅ Cam Rebuild – The main cam system was fully rebuilt, with worn cam tracks, cam tips, and bearings replaced to restore smooth, precise movement of the filling and capping mechanisms. This ensured accurate timing and reliable bottle handling at high speeds.
✅ Capper Rebuild – The capping system underwent a complete overhaul to enhance efficiency and reliability. Key components were replaced or upgraded, including:
- Drive system, spindles, clutches, cam gears, and bearings for smoother operation.
- Cap delivery system to improve consistency, reduce jamming, and ensure precise cap application.
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✅ Electrical & Automation Upgrade – The machine was fully rewired and equipped with a new Allen-Bradley PLC Package. The upgrade included:
- Standalone main electrical enclosure built to IP65 standards, ensuring protection from dust and water.
- Integrated bottle counter and speed indicator for real-time production monitoring.
- Full Line control
✅ Guarding & Safety Enhancements – To ensure operator safety and compliance, critical guarding components were inspected and replaced where necessary:
- Door sensors, fasteners, hinges, handles, panel latches, and V-latch closures were all upgraded to meet safety standards.
✅ Main Drive, Star Wheel Shafts & Infeed System – Key mechanical drive and transfer components were overhauled for reliable long-term operation:
- Motor, gearbox, clutch, gears, lubrication system, and bearings were all inspected and replaced.
- Star wheel shafts, drive shafts, gearboxes, oil seals, chains, belts, and tensioners were examined, ensuring proper alignment and function.
Beyond the filler rebuild
ICON delivered a complete suite of equipment and upgrades to automate the production
✅ Conveyor & Line Diverter System – The conveyor system was supplied in multiple stages to accommodate the different phases of the line. It was designed to handle larger container sizes efficiently. The line diverter was engineered to merge two product streams before feeding them into a case packer, ensuring a smooth and efficient workflow.
✅ Inverter Bottle Washer – Supplied and Installed an inverting bottle washer to wash the bottles while maintaining access to other parts of the line.
✅ Full line control – Full line control managed from the machine HMI.
ICON’s expertise in designing and building….
fillers and upgrading equipment, we provided the client with a fully optimized second-hand filler capable of achieving their required production speed and efficiency goals. This project highlights ICON’s commitment to precision engineering, cost-effective solutions, and extending the lifecycle of industrial machinery. This was part of a full filling line—click here to see the full project.
Staying Updated with Icon Equipment
For businesses looking to stay updated on the latest in liquid filling technology, the Icon Equipment YouTube channel offers insights, demonstrations, and a closer look at the innovations shaping the industry’s future.
We are your solution!
With Australia’s business landscape booming, there’s a growing call for top-notch liquid filling machines. That’s where companies like Icon Equipment step in. They’re not just offering machines; they’re providing solutions tailored to the distinct challenges and aspirations of Aussie businesses.
Contact Icon Equipment today and talk to our professionals for your next filling project! – click here to take action
Contact Details
Icon Equipment International Pty Ltd
13-17 Hillwin Street
Reservoir Vic 3073 Australia
Tel:Â +61 3 9462 1544
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