A co-packer and CPG company came to Morrison to discuss a multipack Febreze line. Originally utilizing 32 people to hand pack the Febreze into cardboard boots at stations, the packaging process was slow, labor intensive, and didn’t present the containers in attractive packaging with the right marketing appeal.
Their team needed a way to automate this process and increase productivity in their operations.
Morrison automated the entire process with a custom-designed grouping, collating, and sleeving solution.
Initially, 1-2 lane dividing screws separated the containers according to their specific pack requirements. Once in the appropriate lanes, the containers were metered and oriented. As the containers moved beneath the machine, you could see them rotating to ensure the handles were uniformly aligned.
After orientation, the timing screws grouped the containers for their respective pack formations. Once grouped, overhead pucks/pallets lowered to securely grip the containers, maintaining a tight package as they were inverted upside down.
In this inverted position, a sleeve was applied to keep the containers together. By using a sleeve, Morrison eliminated the need for a cardboard boot, which not only saved the customer money but also enhanced the package’s appearance, allowing graphics to be placed directly on the sleeve.
The system could handle up to three separate product infeed lanes of Febreze cans, producing bundled packages of 2, 3, or 4 containers. These were shrink-sleeved together and discharged to an outfeed lane. The graphic to the right illustrates the general layout of the machine and its major equipment subgroups.
The system accepted one lane of product directly from production on Lane 1, and up to two additional lanes from inventory on Lanes 2 and 3, with a combined maximum speed of 320 containers per minute. The infeed timing screws grouped the containers into the appropriate pack configuration, while the discharge timing screws oriented them with the trigger trailing. After collation, the containers were picked up by the overhead lug conveyor, inverted, and passed through the sleeve applicators and steam tunnel. Finally, the containers were up righted and released onto a discharge conveyor.
This system was created with plastic UHMW and stainless steel. Providing a lightweight and robust design system that is easy to clean and maintenance.
Morrison’s automated grouping, collating, and sleeving solution significantly improved the productivity and efficiency of the customer’s Febreze packaging line by:
• Labor Reduction: the automated system replaced the need for 32 manual labor positions, reducing labor costs and increasing efficiency.
• Enhanced Packaging: the elimination of cardboard boots in favor of sleeves with direct graphics resulted in more attractive packaging, enhancing marketing appeal.
• Increased Speed: the system achieved a maximum speed of 320 containers per minute, significantly increasing throughput.
• Uniform Orientation: the automated orientation process guaranteed that all containers were uniformly aligned, improving the overall presentation.
• Cost Savings: by removing the need for cardboard boots, the customer saved on material costs while achieving a more visually appealing package.
Overall, the solution provided a streamlined, efficient, and cost-effective method for packaging Febreze containers, aligning with the customer’s goals of increased productivity and improved packaging aesthetics.
"*" indicates required fields
