Star Wheels for Bottle Washers | High-Throughput, Low-Breakage, Long-Life Bottle Transfer Solutions

Star wheels (or bottle transfer stars) are core actuating components in bottle washer conveyors, responsible for precise bottle indexing and timing synchronization throughout the cleaning process. Their performance directly impacts line stability and bottle safety. Structurally, they withstand 5–15N continuous lateral force and ≥50N peak impact. Designed for ≥5 million cycles at 2–3Hz, with safety factor ≥2.5 at critical stress points and notched Izod impact strength ≥8kJ/m² to survive bottle jams. Motion accuracy includes ±0.2mm repeatability, <10ms PLC sync error, and support for ≥12,000 bottles/hour. Dynamic performance features max acceleration of 5–8m/s², natural frequency >80Hz (no resonance), ≥99.8% action success rate, MTBF ≥10,000 hours, and 24/7 operation capability. Modern star wheels integrate precision mechanics with predictive maintenance readiness. Proper selection can boost line efficiency by 10–20%, reduce breakage to <0.01%, and cut annual maintenance costs by 30–40%—making them the true “pace-setter” of high-speed filling lines.