Improving High-Volume Bottling: Solving Corrosion and Print Quality Challenges

Challenge: Water Spills and Unstable Bottles Creating Downstream Issues

In bottled water operations, moisture is unavoidable. During the filling process at Mountain Park Spring Water, routine water spills were exposing an existing conveyor to constant moisture. Over time, this led to corrosion issues that increased maintenance requirements and threatened long term conveyor reliability.

At the same time, Mountain Park Spring Water was experiencing a second, more subtle but equally disruptive problem. An inkjet printer located on the inside radius of a curved conveyor was struggling to produce consistent, readable codes. As bottles traveled through the curve, they wobbled and shifted, causing misaligned or unclear prints. For a high volume beverage operation, poor print quality can quickly become a compliance and rework issue.

These two problems were connected by a common root cause: the limitations of the existing conveyor design in a wet environment with curved product flow. Mountain Park Spring Water needed a solution that addressed both corrosion resistance and product stability without slowing throughput or disrupting the filling process.

Evaluation: Application and Conveying Environment

Trace Davis, the AEC salesman on the project, worked closely with the Mountain Park Spring Water team to understand the operating conditions on the line. The evaluation focused on three critical factors:

1. Presence of constant moisture around the filler discharge. Any replacement equipment would need to withstand frequent exposure to water without degrading over time.
2. Product behavior through the curve. Lightweight plastic water bottles can be especially prone to wobble when transitioning through curves, particularly when the conveyor surface does not provide adequate support or control.
3. Print quality at the inkjet location. The printer itself was not the issue. The inconsistent bottle presentation through the curve was the true culprit, making it clear that the conveyor needed to improve stability through that section of the line.

With these factors in mind, AEC designed a solution that addressed the environment, the product, and the downstream equipment relying on consistent bottle positioning.

Solution: Stable, Corrosion Resistant Conveyor Design

To solve the corrosion issue and stabilize bottle flow, AEC integrated two types of conveyors that worked in tandem to stabilize the line.

1. SpanTech plastic belt curve with a fully stainless-steel frame.
   This conveyor was selected specifically for the curved section leading into the inkjet printer. The plastic belt provides continuous product support through the curve, significantly reducing bottle wobble compared to traditional roller-based conveyors. The stainless-steel frame ensures long term durability in a wet environment, making it well suited for bottled water applications where spills are unavoidable.
2. Hytrol 19GSR gravity roller conveyor with a galvanized finish.
   This conveyor replaced sections that had been affected by corrosion while maintaining a cost-effective solution where full stainless-steel construction was not required. The galvanized finish offers improved resistance to corrosion compared to standard painted frames, extending the life of the conveyor in moisture exposed areas.

Together, these conveyors created a smoother, more controlled product flow while addressing the environmental challenges of the filling area.

Result: Smoother Operation and Clearer Printing

The impact of the new conveyor equipment was immediate. Bottle flow through the curve became noticeably smoother, eliminating the wobble that had been causing inkjet print issues. With bottles traveling in a more stable orientation, the printer was able to apply consistent, readable codes without adjustment.

Equally important, the corrosion issues that had plagued the previous conveyor were resolved. The stainless-steel SpanTech curve and galvanized Hytrol conveyor provided the durability needed for the wet filling environment, reducing maintenance concerns and improving long-term reliability.

Following a minor repair adjustment after installation, Mountain Park Spring Water reported that the system was operating flawlessly.

As Stewart Douglas of Mountain Park Spring Water shared: “It’s been smooth as silk since the repair last week. We love the conveyor. I’m so disappointed it took us 20 years to get one like it. I’m really surprised that design was never offered by anyone before now.”

This project proves that the greatest value AEC provides isn’t the equipment itself, but the technical insight to solve problems. By moving beyond ‘like-for-like’ replacements and focusing on the application, AEC restored the efficiency and print quality that Mountain Park Spring Water had been missing for 20 years; exceeding all expectations.

Maximized: Operational Reliability through Application Targeted Design

The Mountain Park Spring Water project is a strong example of how thoughtful conveyor selection can solve multiple problems at once. By combining a SpanTech plastic belt curve for stability and corrosion resistance with a Hytrol 19GSR conveyor designed for durability, AEC helped our customer improve both operational efficiency and print quality.

For bottled water and beverage producers, conveyor performance directly impacts uptime, product quality, and downstream processes like coding and labeling. Addressing these challenges early with the right equipment can prevent years of recurring issues.

Trace Davis and the AEC team continue to work closely with Mountain Park Spring Water as additional equipment is added to the line, including upcoming Hytrol conveyors. This partnership reflects AEC’s approach to delivering solutions that are tailored to the application, the environment, and the long term goals of the customer.