A major spirits producer in Kentucky was experiencing production disruptions due to downed containers stacking on two bottling lines. When a container tipped over, it often caused additional containers to stack on top of one another, escalating the problem and requiring manual intervention. The issue was present across two different line configurations, each already equipped with one down bottle reject system.
To address both single and stacked downed bottle scenarios, Morrison designed additional down bottle reject guides using stainless steel core plates and reject guide rails with tool-less changeover capabilities. Each line received a custom setup including right and left rail assemblies made with colored UHMW components for quick identification and changeover based on container type—round and square 50 mL bottles, both full and capped.
This system was constructed with:
This solution provided an efficient method for clearing both single and stacked down bottles, reducing the need for manual rework and supporting uninterrupted line flow. Color-coded parts further streamlined operator training and daily operation.
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