High Speed Rotary Filler

High-speed beverage packaging lines are highly complex and expensive, often costing tens of millions of pounds. The most expensive and critical asset on the line is normally the rotary filler.

The core of the filler is the main ring, which picks up the bottles, cans or containers and rotates them firstly into the filling station and then through the closure mechanism – crown capper, screw top or can lid seamer, depending on the container type

What We Monitor.

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Higher quality

Lowe waste

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12 months

Payback Period

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Avoid breakdowns

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Reduce emissions

Review your requirements with one of our consultants.

We’ll help you prepare for the next step in the process, which is a detailed discussion with one of our solution design engineers.

Book an initial discussion


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Consumption data continuously collected from:

  • Inverter Drives
  • Process Control

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Capture key operating data directly from process control systems:
  • Start/Stop
  • Speed (items/minute)
  • Product SKU
  • Short-Stops
  • Faults/Operating Modes

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Monitor leading indicators of failure:
  • Current & Torque: Drive & Gearbox loading
  • Vibration: Lubrication failure, bearing wear and asset movement & stability
  • Lubricant: Oil condition & contamination

Indicative Savings.

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A standard 7.5kW motor running 20 hours/day for 5 days will consume around 38,000 kWhr/annum, costing around£12,000 worth of electricity (June 2022 prices).

Optimising production usage can reduce consumption by 10%reducing electricity cost by £1,200/annum per motor.

High-Speed fillers typically have three drive or pump motors, so savings could be around £3,500

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Avoid scrapped batches of product due to a failure often costing up to £2,500 or more. 

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Where failures go undetected, damage to the main filler ring bearing can result in costly repairs:

  • Replacement main ring bearing cost: £40,000 each
  • Repair labour costs range from £20,000 to £60,000.

Total potential loss from one failure event: £60,000 

Indicative Costs & Payback

95% ROI Payback within Twelve months.

Year 1 cost - £6,300

Annual Monitoring Cost - £1,800*

Hardware costs - £2,000

Commissioning - £2,500

* This represents the filter's share of the monthly ongoing service cost of £995, which includes 100 parameters.


Required hardware will depend on source of consumption data and variables monitored:

  • Process control data available via PLC connections
  • Vibration sensors—minimum of two recommended


Our specialists configure the system and run end-to-end testing prior to go-live.

Monitoring Cost

Share of Annual service fee, based on monitoring 13 parameters for this asset type.
Actual implementation may use more or fewer parameters than this example, depending on requirements.

Download the full Use Case >>

Gain Asset Insight Now

Find out how we can help lower energy usage, enhance reliability and improve operational performance: in a way that is simple, fast and affordable.

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