What Are Decraters?
Decraters (also called uncasers or unpacking machines) extract returnable bottles from plastic or wooden crates at the beginning of a returnable bottle line. They work in conjunction with crate washers and bottle washers to prepare containers for refilling. Used decraters are commonly available as the returnable bottle market evolves.
Decrater Types
- Gripper-head decraters — use mechanical or pneumatic grippers to lift bottles from crates
- Vacuum decraters — use suction cups to lift bottles, suitable for various bottle shapes
- Tilt-type decraters — invert crates to release bottles onto a conveyor
- Servo-driven decraters — modern designs with programmable motion profiles for gentle handling
Critical Inspection Points
- Gripper or suction cup condition — worn components cause dropped bottles and production losses
- Head lifting mechanism — check for smooth operation, bearing condition, and alignment
- Crate conveyor and indexing — crates must be precisely positioned under the extraction head
- Empty crate discharge — verify reliable stacking and discharge of empty crates
- Speed capability — test at rated speed to confirm consistent bottle extraction
Common Issues
Problems to Watch For
- Worn grippers causing bottle drops — the most common issue on used decraters
- Misaligned head causing partial extraction leaving bottles in crates
- Slow cycle times due to worn pneumatic cylinders or fatigued springs
- Crate transport chain wear causing indexing errors
Frequently asked questions
What speed should a decrater match?
The decrater must match or exceed your bottle washer infeed speed. Typical decrater speeds range from 10,000 to 60,000+ bottles per hour depending on the model and crate configuration.
Can a decrater handle different crate sizes?
Most decraters can be adjusted for different crate dimensions and bottle configurations with mechanical setup changes or change parts. Verify compatibility with your specific crate and bottle formats.
Do I need a decrater and a crater?
Returnable bottle lines typically need both: a decrater at the line start to unpack returned bottles, and a crater (or packer) at the end to pack filled bottles back into crates.