EPIC Systems delivered a fully automated, hands-free drum filling line through strategic front-end engineering, custom vision integration, and complete line implementation.
Front-End Engineering & System Design
EPIC began with a detailed preliminary engineering phase to define the most efficient approach, mitigate risk, and establish accurate cost and timeline expectations. The finalized plan integrated:
- Custom dual-camera vision system to locate each drum and precisely identify opening positions
- Packaging line re-design allowing the four-drum sets to remain strapped together from unloading to reloading
- Automated pressure testing to confirm drum integrity and mark defective drums
- Automated cap removal system for consistent, safe opening preparation
- Hands-free filling system to eliminate operator exposure and improve throughput
EPIC recommended advanced line automation combined with machine vision inspection for QA checks, delivering reliability, accuracy, and a safer work environment.
Integrated Engineering & Fabrication
EPIC managed the entire project lifecycle, including:
- On-site assessment & line redesign
- Mechanical, structural, and applied engineering
- Controls engineering and programming
- Internal fabrication and assembly
- Installation, plant integration, FAT, start-up, and operator support
The Packaging Line Integration team partnered closely with the EPIC Vision Lab to ensure the precision required for a completely automated, variable-position filling process.
How the Automated System Works
Automated Vision-Guided Positioning
- Camera 1 locates the four drums and identifies the grid coordinates of each drum’s opening area.
- Camera 2 zooms in to pinpoint the exact location of both openings on each individual drum.
Cap Handling & Pressure Testing
- A magnetic torque wrench tightens one of the two caps, then removes the other.
- A pressure test is conducted by sealing the open hole and injecting air.
- The system expects a pressure switch to flip; if not, it reseals and tests again.
- After two failed attempts, the drum is flagged as defective and bypassed—while the remaining drums in the set continue through the process.
Precision Hot-Fill Operation
- Once a drum passes integrity checks, the filling head automatically positions itself over the open hole.
- Each drum sits on a scale for weight-based filling to exact specifications.
- After reaching target weight, the system mechanically re-torques the cap to a defined standard.
- All four drums are filled simultaneously and travel—still strapped together—back to the forklift for loading.
