Transform Operations with Your Container at the Heart of Your Production Line
When it comes to packaging lines, efficiency is key. That’s where integrated solutions come into play, revolutionizing the way packaging and processing companies manage their operations. But what exactly are integrated solutions?
Integrated Solutions bring together multiple packaging operations and container manipulations into one complete, turnkey system. This includes all the handling of the container as well as the controls programming.
To get the most efficiency, working with an integrator that is well versed in container handling is the best way to impact your throughput positively. While OEMs are the experts in their equipment, you still need to move the containers with control through each step of the process. Integrating equipment must include consideration to how the containers will move on the conveyor from point to point.
Container Handling Expert Integrators consider:
- What position does this container need to be in?
- How can we move it as quickly as possible with control?
- Do we need to combine or divide lanes to allow for more throughput with more equipment?
- What is the path of least resistance for the container that will provide the same output?
- How can the system be designed for future container sizes and provide maximum flexibility?
- What changeover operations are at play, and how can we make them easier?
The benefits of having an expert consider the container at the heart of the integration project speak for themselves. By automating tasks traditionally done by hand, integrated solutions enhance throughput, reduce costly downtime, and improve workplace safety by minimizing the risk of worker injuries. Best of all, these solutions can be tailored to the specific needs of industries as diverse as frozen food, pharmaceuticals, and petroleum.
Curious how integrated solutions with a container handling focus are transforming industries? Let’s explore some real-world examples of how Morrison’s customized integrated solutions have helped industry leaders boost their performance, stay ahead of the competition, and perform complex container manipulations successfully.
Streamlining Insertion of Scoops
Morrison developed an integrated container handling system to address the need for seamless, automated scoop insertion into canisters which reduces human contact with the packaged baby formula. The solution combined an unscrambling mechanism (sorter bowl) with timing screws, creating positive control of containers and scoops for insertion. Scoops and canisters were handled simultaneously, using timing screws to control and time up the processes.
Starting in the sorter bowl, scoops were continuously vibrated to change their orientations for acceptance into the equipment, and upon exiting the sorter bowl, they are either rejected or advanced along the line if they are properly oriented. Using the timing screws, scoops were properly spaced and dropped, one each, into canisters. The system was designed to operate at 350 scoops per minute while fitting within the existing plant layout.
Morrison’s expertise in container handling and controls interfaces enabled smooth integration between equipment, delivering reliability and optimal performance.
Optimizing Ice Cream Packaging
Morrison delivered an integrated solution for Blue Bell Creameries to optimize the multi-packing of ice cream containers. The company had been selling a version of this multi-pack that became difficult to sustain, so transitioned to a new design that is tighter around containers, consistent across runs, and easier to feed through their case packer. Utilizing correctly tailored timing screws, the system grouped stacks of 6 containers into two-packs, ensuring precise control for smooth discharge into the shrink sleeving process. The solution started by turning the containers, grouping them into categories of vanilla and chocolate, and stacking them into 12-packs with 6 of each flavor before shrink sleeving.
Meeting Global Demand for COVID-19 Test Kits
When COVID-19 created an urgent demand for testing, Morrison collaborated with Thermo Fisher Scientific to develop a solution that scaled their test kit production. Initially producing 30–50 tests per minute on four lines, Morrison’s Head of Engineering designed a system that increased production to 120 tests per minute per line. The solution included integration of a Morrison timing screw system throughout the unscrambling, filling, and capping process. Some equipment also include labeling integration. Morrison delivered 32 fully integrated systems globally, meeting the critical demand for COVID-19 testing.
Gas Cylinder Inspection, Rejection, and Mating
Morrison engineered a comprehensive container handling solution to address the need for inspecting and preparing gas cylinders for painting. The system utilized servo-driven timing screws to accept cylinders, Pieper Automation’s vision inspection equipment to rotate them for braze and surface inspection, and lastly discharged them for mating with the downstream overhead magnet chain. A backlog was required for the system to function effectively. Morrison’s design included a reject station to remove defective cylinders from the line, ensuring smooth operation without disrupting production. The system was built to accommodate varied production requirements and was capable of handling both standard and tall cylinders.
Preparing Containers for Code-Dating
Morrison designed a container handling system to accept a single lane of protein shake bottles from a backlog and space them using servo-driven timing screws in preparation for Video Jet’s UV laser code-dating equipment. Cognex’s vision inspection equipment checked for the presence of date codes, and a pneumatic reject station efficiently removed non-compliant bottles without disrupting production. The system, built with hardy stainless steel and durable UHMW plastic, was designed to meet production rate requirements and seamlessly integrate with the customer’s existing laser and inspection equipment.
The Key to Efficiency
At Morrison, we specialize in crafting innovative, integrated solutions that keep your container at the heart of the entire solution. From boosting production speeds to streamlining complex, custom processes, our integrated solutions are built to meet your unique needs while improving efficiency, reducing downtime, and enhancing safety.
With our proven expertise and commitment to reliability through Support Built In®, we’re your partner every step of the way. Ready to transform your operations and unlock your efficiency? Contact us today or request a quote to explore how we can support you!
