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Problems and Remedies Excessive scaling in caustic/soak compartments

i Symptoms: i visible scale on bottle-washer tank walls and heating coils. i difficulty in raising temperature. i Cause/s: i insufficient sequesterants in the bottle-wash solution to handle the hardness i Remedies: i increase sequestrant levels by the addition of additives to overcome insolubility

of calcium with rise in temperature.

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Difficulty to raise temperature in caustic zones


i Symptoms: i long time to reach desired temperatures at start up. i difficulty in maintaining temperature during operations. i Cause/s: i build up of scale on heating coils. i clogged steam traps. i large quantities of suspended solids reaching heating coils. i Remedies; i Check and clean clogged steam traps. i Ensure adequate sequestrant level in bottle wash solution to handle

incoming .

i Check for insoluble materials in the bottle-wash solution. If the levels of

insoluble materials are in excess of 6%, the solids need to be removed by settling , filtering or centrifuging.

i If solids cannot be removed consider discarding solution and start with

starting with fresh solution.

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Scale up of walls in rinse section


i Symptoms: i scale on walls. i scale deposits on bottles. i Cause/s: i carbonates from carry-over detergent precipitate with hardness ions in

the rinse water.

i Remedies: i add suitable threshold inhibitor to the rinse sections. i check the water Ryzner index and adjust pH by suitable addition of an acid

to bring the Ryzner index in the low scaling tendency range.

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White film on bottles


i Symptoms: i appearance of white films on bottles.

i Cause/s: i acid insoluble films i precipitation of aluminates from soak sections caused by high levels of

aluminates (>1.5%) in caustic carry over and pH drop by dilution. Aluminum oxides do not dissolve in acids. i Large quantities of insoluble label filler/pulp in the caustic solution which dry on bottles especially during stoppages. i insufficient rinsing. i tank solution levels low, leaving many bottles above the solution during stoppages.

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White film on bottles


i Remedies: i check aluminate levels in the caustic. If levels are greater than 1.5% discard

and replace with fresh solution or dilute with fresh caustic. i check the level of the insoluble solids in the caustic solution. If levels are in excess of 6%, solids should be removed by settling, filtering etc., or replace with fresh caustic solution. i check alignment, pressure and flow to the water spray rinse jets. i check liquid levels in caustic and rinse tanks..

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White film on bottles


i Symptoms: i appearance of white films on bottles.

i Cause/s: i acid soluble i carbonate scale i Remedy: i check carbonate levels in the caustic. change all or part of used caustic with

fresh to reduce carbonates. i add threshold inhibitor to the water in the rinse section. i check reclaim system to ensure for proper settling of solution.

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Bottles not cleaned


i Symptoms: i visible marks or foreign objects. i bottles exiting pasteurizer show excessive foam levels (foam pick). i Rust ring around neck. i Cause/s: i i i i i

unusually dirty/ ditch bottles. bottlewasher running too fast, insufficient soak time. caustic concentration low/improper additives. temperatures too low. improper additive to remove rust ring or other specific soils.

i Remedies: i i i i i
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separate bottles and treat separately. increase caustic concentration. check bottlewasher speed rating. adjust additives level. increase temperature.

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Labels not removed


i Symptoms: i whole labels left attached to the bottles after passing through the bottle washer. i Cause/s:

change in label stock, protective coating that resists caustic. change to a different label adhesive. low caustic concentration in compartments. insufficient soak time in the caustic caused by high machine speed or low solution levels in the tanks. i low temperatures. i excess foam floating the labels.
i i i i i Remedies: i i i i

score label to allow caustic to penetrate coating. check and adjust the concentration and temperature in the caustic tanks. check the speed of the bottle washer. ensure that the solution levels in the tanks are maintained and check levels during the label removal sequence.

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Labels detached from the bottle but carried over to discharge


i Symptoms: i large quantity of detached labels exiting with the discharged bottles. i Cause/s: i unusually large labels caught between bottle and pocket. i insufficient return flow to remove labels caught between the bottle and pocket. i label removal sequence for the different compartments improperly set. i Remedies: i ensure the circulation of caustic is evenly distributed and creates sufficient

turbulence to create sufficient flow between the bottles and pockets. i check and set the label removal sequence for the different compartments to ensure that the compartments where the labels drop off the most are getting the most label removal time.

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Labels accumulating in the caustic compartments


i Symptoms: i large quantity of detached labels accumulating in the caustic compartments. i Cause/s: i insufficient circulation to create turbulence throughout the caustic

compartment. i label removal sequence for the different compartments improperly set allowing labels to accumulate and clog caustic circulation valves and lines. i insufficient capacity of label filter/strainer. i blocked strainer/filter.
i Remedies: i ensure the circulation of caustic is evenly distributed and creates sufficient i i i i
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turbulence to keep labels moving. check and set the label removal sequence for the different compartments to ensure that the compartments where the labels drop off the most are getting the most label removal time. de-scale strainer. resize filter/strainer check paddle operation

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Large number of bottles broken


i Symptoms: i excessive foam picks i large numbers of broken bottles. i Cause/s: i liquid levels in the tanks too low to give the bottles sufficient time to fill with

caustic and trapping air which can float the bottles out to the pockets. i large temperature variance between compartments causing the bottles to break.
i Remedies: i check levels of caustic solution especially during the label removal cycle. i check and adjust temperatures.

foam picks bottles removed automatically or manually after filling because they show a high foam level above the liquid. Often due to foreign matter, soil or glass, in the bottle causing a nucleating site for gas to come out of solution.

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Excessive foaming
i Symptoms: i foam overflows from the caustic compartment especially the caustic jet

compartments. i suspended particles left in the bottles. i deposits formed on bottles by dried foam during stoppages caused by dried foams especially during stoppages.
i Cause/s: i soils in caustic solution cause a lowering of surface tension causing foam. i low levels of solution. i Poor seal on the caustic circulation or jet pumps introducing air to the caustic

solution causing it to foam.


i Remedies: i add defoamer on a time basis especially to the jetting zones. i choose caustic blend with a de-foamer incorporated. i check and repair seals on the circulation and jet pumps.
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Scaling on pockets and chain


i Symptoms: i heavy scale on the pockets and chain. i increase in caustic consumption by excess carry-over. i Cause/s: i scale forms as a result of carry-over caustic containing carbonates precipitating

with the hardness of the rinsing water.


i Remedies: i increase level of threshold inhibitor to the rinse section. Scale is slowly

removed from pockets and chain over a few days. i add a suitable acid product to adjust the pH to so that the water has a slight scaling tendency as rated on the Ryzner index

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