The starch was being filled with fillers not built to handle the product, resulting in 40% of rejected containers due improper fills.
Morrison worked with a filling company to integrate this system independently of one another. Our engineers designed a cantilever divider that would divide the containers into two lanes for filling. The containers are indexed 4 cycles at a time during the filling process so they can be half filled, indexed again so they can be fully filled. This was implemented to reduce the fill time while also create more accuracy.
They are then metered with proper spacing for accurate measures of weight on the check weigher. After verification of proper weight, the containers are then combined again into one single lane.
Starch is a challenging product to handle due to its chemical make up, resulting in any electrical charge being volatile. Morrison’s electrical engineers built a safer control system that would allow this product to be handled safely and keep operators safe as well by maintaining a blast radius of 10 feet.
A reject system is placed after the combining, rejecting the specific container that was not noted as the proper weight.
Note: in this video, caps are on the containers. During testing, caps were off the containers so we could maintain accurate mock environments they would normally run in.
This system was created from Black Anodized Aluminum.
Morrison’s solution significantly reduced the rejection rate by improving the accuracy of the fill process. The innovative cantilever divider and indexing system optimized fill times and ensured precise filling. The enhanced safety measures provided a secure working environment, addressing the challenges posed by handling starch. The reject system further improved the efficiency of the production line by removing improperly filled containers. This solution not only met the customer’s immediate needs but also demonstrated Morrison’s capability to develop tailored, effective container handling systems in challenging environments.
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