Blue Bell Creameries, a major ice cream manufacturer, needed an automated multi-packing solution for single-serve ice cream cups. They relied on manual hand-packing for single-serve ice cream containers, but the process presented challenges. Stacks often shifted or toppled inside bags, making storage difficult and requiring significant labor. To address this, Blue Bell sought an automated solution to stack containers six high, pack them into secure sleeves, and enhance shelf appeal.
The new system needed to handle two flavors discharged from spiral freezers at elevated heights, merge lanes, and transition products seamlessly to downstream sleeving. This streamlined process aimed to reduce labor, boost efficiency, and deliver a more retail-friendly presentation.
Morrison designed a turnkey product handling system tailored to Blue Bell’s specific requirements:
• Dual Lane Entry and Stacking: The system accepted containers from two spiral freezer discharges, using timing screws to create consistent single-file lanes. Containers were stacked six high with servo-controlled stacking elevators, providing accuracy and stability during the stacking process.
• Elevation Drop: The stacks were carefully lowered approximately 15 feet using servo-driven starwheels and elevators, maintaining complete control and minimizing product shifts.
• Lane Merging and Orientation: Stacks from both lanes were synchronized and merged into a single common lane using servo-driven lug conveyors. The alternating flavor patterns were established through gradual and precise lane combination.
• Downstream Integration: Once merged, the stacks were grouped into pairs and transferred to Tripack’s infeed conveyor for sleeving. A rejection mechanism, guided by photo-eye sensors, ensured only correctly stacked containers advanced to the next stage, maintaining efficiency and product quality.
• Customization for Future Flexibility: Morrison’s design accounted for potential line accumulations, allowing for improved manufacturing flexibility and reducing downtime caused by production flow interruptions.
Morrison meticulously designed the system to mimic the unique environment of the Blue Bell plant, providing seamless integration and optimal performance.
• Spiral Freezer Integration: To simulate the plant setup, Morrison incorporated a spiral freezer during testing, replicating the exact discharge conditions and container flow. This allowed the system to operate flawlessly under real-world conditions.
• Custom-Built Framework: The system was constructed with durable stainless steel and UHMW plastic, providing the necessary strength and hygiene standards required for dairy production. The materials were selected to withstand the cold, moist environment typical of spiral freezer operations.
• Precision Testing: Morrison conducted extensive in-house testing to refine the system’s performance. The testing accounted for environmental factors such as temperature, humidity, and the physical properties of the containers.
• Operator Accessibility: Recognizing the elevated infeed location, Morrison designed the system to minimize operator interaction by incorporating automation throughout the process, from stacking to lane merging.
• Adaptability: The system was engineered to be robust and adaptable, accommodating potential future modifications such as line accumulation or production line reconfiguration.
By dedicating resources to closely mirror Blue Bell’s production environment, Morrison delivered a solution that seamlessly transitioned from testing to real-world application, providing reliability and efficiency from day one.
The automated handling system delivered measurable improvements:
• Enhanced Efficiency: The system achieved a steady rate of 70 containers per minute, seamlessly managing the stacking and merging process.
• Reduced Workforce Needs: Automation significantly decreased manual intervention, streamlining production and reducing labor costs.
• Minimized Errors and Reduction in Product Waste: By employing precise rejection mechanisms and servo-controlled operations, only correctly stacked containers advanced downstream, providing high product quality, reducing downtime due to incorrect stacks, and reducing wasted product.
• Reduced Manual Intervention: Automation significantly decreased operator involvement, streamlining production and reducing labor costs.
• Operational Reliability: The robust design minimized stoppages and maintained consistent throughput, even during production line interruptions.
• Customer Satisfaction: Morrison’s solution met Blue Bell’s specific needs, enabling reliable multi-packing of two flavors into alternating stacks, while maintaining the product’s integrity.
• Improved Shelf Appeal: Transitioning to sleeved packaging ensured better display stability and enhanced the product’s presentation for retail.
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