A nicotine product manufacturer required a custom can stacking system to create 5-pack configurations prior to a downstream sleeving operation within a regulated tobacco and nicotine packaging environment. The container handling system needed to accept five lanes of chewing nicotine pouch cans discharged from an existing accumulation table and transferred through customer-provided vertical, gravity-fed twist chutes.
Following stack creation, the grouped cans had to be pitched out to consistent centerline spacing to match the downstream platform conveyor requirements. The solution needed to operate at production speeds of up to 250 containers per minute. Maintaining synchronized multi-lane flow and precise discharge spacing was critical to supporting stable sleeving performance and overall packaging line operation.
As a custom timing screw manufacturer, Morrison engineered a custom stacking and metering timing screw drive unit designed to accept five lanes of backlogged nicotine pouch cans from vertical, gravity-fed chutes. The system incorporated a guiding mechanism that rotated each can 90 degrees, selected one can from each lane, and formed controlled 5-pack stacks prior to horizontal transfer.
Once the containers transitioned into the plastic guides, synchronized timing screws provided positive container control and precise metering. This timing screw system maintained alignment and consistent spacing as the stacked cans advanced toward the sleeving operation.
To maintain stack integrity prior to sleeving, Morrison implemented a multi-level star wheel system that stabilized and aligned the stacked nicotine pouch cans before entering the steam tunnel process.
For full-line synchronization, a servo motor was integrated on the lug conveyor and operated as the master drive. The timing screws were electronically synchronized to the lug conveyor to maintain coordinated motion across the system. Ready-to-run signals were exchanged between machines via Ethernet or I/O-based communication to maintain proper line integration and timing control.
Following discharge from the steam tunnel, Morrison incorporated dual reject stations to manage sleeve quality conditions. One reject station diverted product into Customer Bin A if the downstream equipment stalled, meaning it could no longer accept additional product. This reject allowed the line to maintain efficiency without discarding product, because the sleever and steam tunnel could continue running while operators collected work-in-progress (WIP) product. Operators could then reintroduce this WIP to the downstream equipment once the line resumed normal operation. A second reject station, equipped with inspection, diverted containers into Customer Bin B. This reject removed product that did not meet quality standards required for proper brand recognition in the marketplace. By separating these containers from the main flow, the design supported controlled product handling and helped maintain an orderly downstream workflow.
The multi-lane timing screw system was constructed using stainless steel timing screw bracketry and a stainless steel structural base frame designed for durability and stability in nicotine pouch packaging environments. Timing screws, chutes, guides, and starwheels were designed and manufactured from FDA-compliant materials, primarily UHMW and Delrin® (acetal). The approach reinforced Morrison’s expertise in custom container handling equipment.
The system utilized Morrison’s timing screw drive units to provide synchronized, servo-controlled motion across the stacking and metering components. A timing belt and gear drive configuration provided synchronized motion control across all stacking and metering components. Slotted adjustable stainless steel mounting angles allowed precise alignment and integration with the customer’s lug conveyor.
The system included a self-standing perimeter guarding structure constructed from stainless steel and Lexan, featuring access doors and interlocked safety switches tied into Morrison’s control system. The guarding integrated directly with the structural base frame, supporting safe operation and full system accessibility.
The multi-lane timing screw system supported production speeds of 250 containers per minute while forming consistent 5-pack stacks for downstream sleeving. The synchronized timing screws and star wheel assembly maintained stack integrity and discharged product at a precise pitch to match the platform conveyor requirements.
By implementing independent servo drives for each primary operation—including the left- and right-hand timing screw systems and the star wheel assembly—the system provided increased operational flexibility and simplified synchronization across the packaging line. Electronic coordination between the lug conveyor and timing screw drives supported controlled product flow and consistent stack transfer into the steam tunnel.
The servo-driven architecture reduced reliance on complex mechanical linkages, contributing to lower mechanical wear and simplified maintenance requirements. The final system delivered stable multi-lane stacking, reliable pitch control, and improved integration with upstream and downstream equipment within high-speed tobacco product packaging operations.
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