Case Study

Combining + Turning Gable-Top Containers

Operating Speed: 50 CPM

Container: 32 oz

Customer Container Handling Challenge 

Dairy manufacturing company Garvey Corporation required a specialized solution for handling gable-top containers with spout caps. Their production line featured two lanes, one with the spout cap on the right side of the gable top and the other with the spout cap on the left. The challenge was to turn one lane 180 degrees and combine the lanes so all containers faced the same direction after merging. Additionally, the system needed to handle square paperboard containers efficiently, meet specific throughput requirements, and fit within the customer’s existing setup.

Morrison Solution 

Morrison designed a custom system to address this unique container handling challenge. The solution included:

Timing Screws: Six sections of timing screws made of 6” OD UHMW plastic, totaling 84” in length. These screws provided smooth handling and accurate positioning of the containers.
Motor and Gearbox: Four AB VPF epoxy-coated servo motors with servo reducers provided precise control for container orientation and lane merging.
Backlog Management: The system integrated backlog control to maintain consistent operation and prevent jams.
Mounting and Adjustability: A stainless steel structural base frame and all necessary hardware were included for secure mounting to the customer’s conveyors.
Change Parts: Dedicated to one container size, the system included guiderails integral to Morrison’s design for reliable transitions.
Clutch Functionality: The servo motors were programmed to act as a clutch, monitored through the customer’s controls.

Construction 

The system was constructed from low-washdown stainless steel, designed for use with low-pressure cleaning using mild soap and water. This construction provided durability and compliance with the production environment’s ambient conditions.

Results

Morrison’s innovative solution enabled the dairy manufacturer to efficiently orient and merge gable-top containers at a combined throughput of 100 containers per minute. Key benefits included:

Improved Efficiency: Seamless lane merging and orientation provided consistent downstream processing.
Enhanced Flexibility: The system handled square paperboard containers with precision, meeting the required throughput of 50 CPM per lane.
Reduced Downtime: Reliable guiderails and precise servo motor control minimized disruptions during operation.
Adaptability: The design accommodated the existing plant setup, with clear specifications for conveyor requirements and guarding options.

Ultimately, Morrison delivered a robust and efficient system that met the customer’s production goals, improved line performance, and provided proper container orientation for seamless operations.