An alcohol manufacturer required a solution to improve efficiency on their production line, specifically for combining Crow Royal bottles from two lanes into a single lane. The bottles included four different sizes of Crown Royal: 375ml, 750ml, 1L, and 1.75L. These heavy, empty glass containers posed a unique challenge due to their varying sizes and the need to maintain precise handling and control during the merging process. Additionally, minimizing downtime and maximizing throughput were critical for this operation.
To address this challenge, Morrison’s engineering team designed a custom system utilizing eight timing screws with a quick-change design. Each screw, measuring 42” in length and 5” in diameter, was constructed from UHMW material to provide durability and smooth operation. The quick-change design eliminated the need for tools during changeover, enabling faster changeovers between bottle sizes.
A key feature of the solution was the integration of servo motors and controls, allowing each lane to operate independently. This innovation allowed containers to be combined outside the screws, reducing the wear on the screws and enhancing overall system performance. By separating the merging process from the screws, Morrison minimized downtime and boosted throughput, meeting the manufacturer’s high-speed production demands.
The timing screw system was designed with versatility and durability in mind. The screws’ UHMW construction provided a lightweight yet robust solution, ideal for handling heavy glass bottles without risking damage to the container and reducing chances of micro-fractures in the glass. Servo motor controls allowed precise adjustments and seamless transitions between different container sizes, further enhancing the system’s efficiency.
Morrison’s innovative solution delivered significant improvements for the manufacturer’s production line. The quick-change timing screw system and servo-driven controls streamlined the combining process, enabling faster changeovers and reducing downtime. By providing precise handling of all four container sizes, the solution achieved higher throughput and a more efficient operation overall. The manufacturer successfully overcame the challenges of merging two lanes of varying-sized glass bottles into one, all while maintaining consistent performance and reducing operational bottlenecks.
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