Automating Machine Cleaning for Maximum Uptime at Berry Global
Berry Global wanted to reduce injection molding machine downtime caused by widespread production stops needed to clean the machines’ covers manually. Keeping these surfaces clean was crucial due to the company’s adherence to strict FDA standards. The existing cleaning process involved workers using boom lifts and Swiffer mops to remove the debris. Although the process seems quick and easy, it often spreads the debris, creating a larger mess throughout the plant.
Berry Global challenged our team to develop an automated cleaning solution that would enable uninterrupted production while requiring minimal oversight. The goal was to maximize uptime and minimize the risk of work-related injuries.
The Challenge
Image 1: Surfaces to be Cleaned
The Approach
During the ideation phase, one option we explored was applying sticky films to the covers. When a swap was warranted, the operator could quickly peel up the dirty film and replace it with a new one. We abandoned this “budget” solution due to its lack of reusability and higher-than-desired worker input.
After sifting through different reusable ideas, we settled on an electromechanical system whose design was inspired by observing how 3D printers function. Our first model, created using SolidWorks, consisted of stepper motors, lead screws, ball bearings, and custom brackets. Our goal in selecting or designing these components was to prioritize simplicity and reliability while ensuring easy access to replacements in case of failure.
V1 Design Operation Video
The preliminary design underwent multiple revisions over the months of development. One significant change was replacing the rotating brush with a fixed one. Another was replacing eight ball bearings, which guided the sweeping apparatus ensuring smooth operation, with two friction-damping sliders. These design improvements reduced assembly complexity, offered cost savings, and lowered the risk of assembly failure.
Image 2: V2 Design Full Assy View
To precisely control the motion of the cleaning apparatus, we leveraged an Arduino microcontroller programmed in C++. Our user-friendly code allowed operators to adjust sweeping speed and frequency, enabling a tailored cleaning process for optimal efficiency.
Image 3: V2 Design Side Assy View
Image 4: V2 Design Physical Prototype
Our solution gave Berry Global the tools necessary to produce an additional 72,000 units annually.
