Customer Container Handling Challenge 

The customer needed a puck loading solution to transfer a single lane of lightweight containers onto a puck conveyor for sleeving. Due to the short height and low weight of the containers, maintaining consistent spacing and orientation was difficult. The system had to operate within a tight footprint and accommodate precise tolerances for sleeving, while also managing backlog conditions without disrupting product flow.

Morrison Solution 

A servo-driven dual timing screw system was developed to meter containers at a 4.5-inch discharge pitch and place them onto the puck conveyor. The screws were designed to handle the containers gently and consistently, even in high-speed conditions. Optional smart feed upgrades were offered to dynamically respond to backlog scenarios, using additional screws to gradually accelerate product flow. The system also included quick-change features and deluxe adjusters for flexibility across container sizes.

Construction 

The system was built with black anodized aluminum bracketry, UHMW (ultra-high-molecular-weight polyethylene) timing screws, and stainless-steel guarding. It featured a structural stainless steel base frame, polished stainless steel dead plate for smooth transitions, and a 6-foot infeed conveyor with adjustable guiderails. Safety was addressed through interlocked guarding and overload-responsive servo motor controls. All components were designed for easy integration with existing puck conveyors.

Results

The solution provided consistent container spacing and reliable puck placement, supporting high-speed sleeving operations. The compact design fit within the customer’s space constraints, while the smart feed option offered enhanced control over product flow during backlog conditions. The quick-change and adjustability features reduced downtime and improved adaptability for future container variations.