Quick-Change Twist Blocks for Seamless Container Changeovers

Operating Speed: Up to 300 Containers per Minute

Customer Container Handling Challenge 

The customer needed a way to transfer a range of full/lidded tapered plastic cups—ranging from 15oz to 80oz—between conveyors without disrupting line flow. The challenge was especially prevalent with larger, more tapered containers, which tend to wobble or misalign during transitions. A fast changeover process was also critical, as multiple container sizes were used on the same line.

Morrison Solution 

A twist block system was designed to guide each container size smoothly between conveyors. For the first four sizes, twist blocks were mounted between conveyors. For the oversized 80oz cup, a prototype block was developed to sit directly on the conveyor due to its unique shape. A quick-change mounting plate was included to support quick changeovers between container sizes, minimizing downtime during the process.

Construction 

Each twist block assembly was built with robust mounting components and tested with the real containers prior to shipment. The support provided to the customer included:

Precision-machined components for container-specific fits
Operational video with setup and cleaning instructions
Fit testing with customer containers before delivery

Results

The Twist Block system enabled the customer to:

Handle multiple container sizes with minimal downtime
Reduce changeover time using a quick-change mounting plate
Maintain consistent container orientation between conveyors
Prototype and validate on-conveyor handling for large containers

This modular approach provided flexibility for future container changes and supported efficient line performance without requiring extensive reconfiguration.