How to Choose the Right Accumulation Equipment Solutions
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This webinar is an overview of the common types of accumulating conveyors and accumulation equipment used in the packaging and process industries. Discover best use practices and pitfalls of each type of equipment as well as bracket pricing information.
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How to Choose the Right Accumulation Equipment Solutions
- 1. How to Choose the Right Accumulation Solution Nercon Eng. & Mfg., Inc. presents:
- 3. Accumulation Solutions PRODUCTS □ Round □ Non-Round □ Package SEQUENCE □ FIFO □ FILO □ Random CONTROLS □ Simple □ Complex COST □ $ □ $$ □ $$$ Round Non-Round Packages
- 4. Accumulation Solutions PRODUCTS □ Round □ Non-Round □ Package SEQUENCE □ FIFO □ FILO □ Random CONTROLS □ Simple □ Complex COST □ $ □ $$ □ $$$ FIFO = First-In, First-Out FILO = First-In, Last-Out
- 5. Accumulation Solutions PRODUCTS □ Round □ Non-Round □ Package SEQUENCE □ FIFO □ FILO □ Random CONTROLS □ Simple □ Complex COST □ $ □ $$ □ $$$ Simple Controls Complex Controls
- 6. Accumulation Solutions PRODUCTS □ Round □ Non-Round □ Package SEQUENCE □ FIFO □ FILO □ Random CONTROLS □ Simple □ Complex COST □ $ □ $$ □ $$$ $ = less than $50,000 $$ = from $50,000 - $100,000 $$$ = over $100,000
- 8. Conveyor Solutions PRODUCTS □ Round □ Non-Round □ Package SEQUENCE □ FIFO □ FILO □ Random CONTROLS □ Simple □ Complex COST □ $ □ $$ □ $$$ Tabletop Chain Conveyors X X X X X X Round Non-Round Package
- 9. Conveyor Solutions Table Top Accumulation Case Packer Labeler 1 Labeler 2
- 10. Conveyor Solutions Table Top Serpentine Conveyor Serpentine System PRODUCTS □ Round □ Non-Round □ Package SEQUENCE □ FIFO □ FILO □ Random CONTROLS □ Simple □ Complex COST □ $ □ $$ □ $$$ X X X X X X
- 11. Conveyor Solutions Table Top Serpentine Conveyor Case Packer Labeler 1 Labeler 2
- 12. Conveyor Solutions Serpentine Table PRODUCTS □ Round □ Non-Round □ Package SEQUENCE □ FIFO □ FILO □ Random CONTROLS □ Simple □ Complex COST □ $ □ $$ □ $$$ X X X X X X
- 13. Conveyor Solutions Serpentine Table Bi-Di cleaner Filler Serpentine Table
- 14. Conveyor Solutions Mass Flow Conveyors PRODUCTS □ Round □ Non-Round □ Package SEQUENCE □ FIFO □ FILO □ Random CONTROLS □ Simple □ Complex COST □ $ □ $$ □ $$$ X X X X X
- 15. Conveyor Solutions LBP Chain Conveyors PRODUCTS □ Round □ Non-Round □ Package SEQUENCE □ FIFO □ FILO □ Random CONTROLS □ Simple □ Complex COST □ $ □ $$ □ $$$ X X X X X X
- 16. Conveyor Solutions Zoned Accumulation: Zero Pressure Lift PRODUCTS □ Round □ Non-Round □ Package SEQUENCE □ FIFO □ FILO □ Random CONTROLS □ Simple □ Complex COST □ $ □ $$ □ $$$ X X X X
- 17. Conveyor Solutions Multi – Lane Systems PRODUCTS □ Round □ Non-Round □ Package SEQUENCE □ FIFO □ FILO □ Random CONTROLS □ Simple □ Complex COST □ $ □ $$ □ $$$ X X X X
- 18. Conveyor Solutions Multi Lane Conveyors Gated System PRODUCTS □ Round □ Non-Round □ Package SEQUENCE □ FIFO □ FILO □ Random CONTROLS □ Simple □ Complex COST □ $ □ $$ □ $$$ X X X X X
- 19. Conveyor Solutions Multi Lane Conveyors Filler Unscrambler
- 20. Conveyor Solutions Now, we’ll take some questions for what we have covered so far.
- 22. Conveyor Solutions Recirculating Accumulation Table Machine Solutions PRODUCTS □ Round □ Non-Round □ Package SEQUENCE □ FIFO □ FILO □ Random CONTROLS □ Simple □ Complex COST □ $ □ $$ □ $$$ X X X X X Re-Flow Accumulator
- 23. Conveyor Solutions Recirculating Accumulation Table Machine Solutions
- 24. Conveyor Solutions Recirculating Accumulation Table Machine Solutions Garvey Infinity Table
- 25. Conveyor Solutions Recirculating Accumulation Table Machine Solutions PRODUCTS □ Round □ Non-Round □ Package SEQUENCE □ FIFO □ FILO □ Random CONTROLS □ Simple □ Complex COST □ $ □ $$ □ $$$ X X X X X
- 26. Conveyor Solutions Bi-Directional Accumulation Table Machine Solutions PRODUCTS □ Round □ Non-Round □ Package SEQUENCE □ FIFO □ FILO □ Random CONTROLS □ Simple □ Complex COST □ $ □ $$ □ $$$ X X X X X Bi-Di Table
- 27. Conveyor Solutions Bi-Directional Accumulation Table Machine Solutions Bi-Directional Table cleaner Filler Serpentine Table
- 28. Conveyor Solutions Variable Length Accumulators Machine Solutions PRODUCTS □ Round □ Non-Round □ Package SEQUENCE □ FIFO □ FILO □ Random CONTROLS □ Simple □ Complex COST □ $ □ $$ □ $$$ X X X X X X Flex Flow Accumulator
- 29. Conveyor Solutions Variable Length Accumulators Machine Solutions
- 30. Conveyor Solutions Variable Length Accumulators Machine Solutions
- 31. Conveyor Solutions Variable Length Accumulators Machine Solutions
- 32. Conveyor Solutions Variable Length Accumulators Machine Solutions
- 33. Conveyor Solutions Variable Length Accumulators Machine Solutions
- 34. Conveyor Solutions Variable Length Accumulators Machine Solutions Hartness – Dynac System
- 35. Conveyor Solutions Alpine Accumulator Machine Solutions PRODUCTS □ Round □ Non-Round □ Package SEQUENCE □ FIFO □ FILO □ Random CONTROLS □ Simple □ Complex COST □ $ □ $$ □ $$$ X X X X X X
- 36. Conveyor Solutions Alpine Accumulator Machine Solutions
- 37. Conveyor Solutions Vertical Accumulator Machine Solutions PRODUCTS □ Round □ Non-Round □ Package SEQUENCE □ FIFO □ FILO □ Random CONTROLS □ Simple □ Complex COST □ $ □ $$ □ $$$ X X X X X
- 38. Conveyor Solutions Vertical Accumulator Machine Solutions PRODUCTS □ Round □ Non-Round □ Package SEQUENCE □ FIFO □ FILO □ Random CONTROLS □ Simple □ Complex COST □ $ □ $$ □ $$$ X X X X X Dual - Flight
- 39. Conveyor Solutions Vertical Accumulator Machine Solutions PRODUCTS □ Round □ Non-Round □ Package SEQUENCE □ FIFO □ FILO □ Random CONTROLS □ Simple □ Complex COST □ $ □ $$ □ $$$ X X X X X Single Flight
- 40. Conveyor Solutions Vertical Accumulator Machine Solutions
- 41. Conveyor Solutions Square Box Accumulator Machine Solutions PRODUCTS □ Round □ Non-Round □ Package SEQUENCE □ FIFO □ FILO □ Random CONTROLS □ Simple □ Complex COST □ $ □ $$ □ $$$ X X X X
- 42. Conveyor Solutions Square Box Accumulator Machine Solutions
- 43. Serpentine Accumulator Machine Solutions PRODUCTS □ Round □ Non-Round □ Package SEQUENCE □ FIFO □ FILO □ Random CONTROLS □ Simple □ Complex COST □ $ □ $$ □ $$$ X X X X X X X Rolco Serpentine Accumulator
- 44. Conveyor Solutions Serpentine Accumulator Machine Solutions PRODUCTS □ Round □ Non-Round □ Package SEQUENCE □ FIFO □ FILO □ Random CONTROLS □ Simple □ Complex COST □ $ □ $$ □ $$$ X X X X X X X
- 45. Conveyor Solutions Serpentine Accumulator Machine Solutions PRODUCTS □ Round □ Non-Round □ Package SEQUENCE □ FIFO □ FILO □ Random CONTROLS □ Simple □ Complex COST □ $ □ $$ □ $$$ X X X X X X X
- 46. Conveyor Solutions Serpentine Accumulator Machine Solutions PRODUCTS □ Round □ Non-Round □ Package SEQUENCE □ FIFO □ FILO □ Random CONTROLS □ Simple □ Complex COST □ $ □ $$ □ $$$ X X X X X X X
- 47. Conveyor Solutions Serpentine Accumulator Machine Solutions
- 48. Conveyor Solutions Serpentine Accumulator Machine Solutions
- 49. Conveyor Solutions Multi Level Accumulator Machine Solutions PRODUCTS □ Round □ Non-Round □ Package SEQUENCE □ FIFO □ FILO □ Random CONTROLS □ Simple □ Complex COST □ $ □ $$ □ $$$ X X X X
- 51. Decision Matrix
- 52. Decision Matrix Application Stand Up Pouch for cookies: cannot be backed up FIFO Need 2 min. of accumulation Must sense upstream and downstream fluxes Budget is under $100,000 Either vertical or horizontal space is available
- 53. Decision Matrix
- 54. Decision Matrix
- 55. Decision Matrix
- 56. Conveyor Solutions Variable Length Accumulators PRODUCTS □ Round □ Non-Round □ Package SEQUENCE □ FIFO □ FILO □ Random CONTROLS □ Simple □ Complex COST □ $ □ $$ □ $$$ X X X X X X Flex Flow Accumulator Decision Matrix
Editor's Notes
- Moderator : We’ll be starting in a few minutes for the webinar on “How to Choose the Right Accumulation Solutions” – presented by Nercon. My name is Joyce Fassl, and I’m your moderator from Food Manufacturing. Before our introductions of Nercon’s accumulation specialists, I want to direct you to the Text Questions to the right of your screen. Let’s test the question utility now and type your answers to the question: Why are you taking this webinar today? -pause- Nercon appreciates your responses. We hope that this presentation can help you to learn more about the types of accumulation technology available and what is best for your packaging line. So why don’t we begin by introducing the presenters from Nercon so they can address some of these questions and concerns that you are having about accumulation.
- JIM: Thank you JOYCE. We’re going to be talking about the different types of conveyor solutions and machine solutions that are commonly used for accumulation. This is a continuation of last Aug. presentation –Mistakes to avoid when planning for accumulation. Theory vs. Mechanics We’ll include a criteria chart on all the solutions. We discuss best use scenarios and things to avoid with each solution We will cover the capabilities of the conveyors and machine solutions, including controls We will provide budgeting, order of magnitude pricing We will also have a decision matrix example which is also available for download
- Jim: Before we get started, I want to draw your attention to the criteria chart ,located on the right side of the slide-highlighted in blue, that will be shown throughout the presentation. Round Containers: rounds shapes like bottles and cans Non-round containers: Ovals and shapes with rounded corners Packages: Cartons, trays or bags, basically products or package shapes besides rounds and ovals.
- Jim: FIFO mean First-In First Out which refers to the product sequence. FIFO also includes conveyors and machines that accumulate in slugs or groups in sequence. FILO means First in – Last Out Random: Many of the accumulation solutions fall somewhere in between
- Jim: Also refer to the chart when we are talking about controls. Simple controls : Stop start stations Do not have smart control Complex controls Complex controls refer to line integration and equipment monitoring Human interface Control Logix
- Jim: Bracket Pricing One Dollar Sign $ = less than $50,000 capital purchase cost Two Dollar Signs $$ = from $50,000 - $100,000 Three Dollar Signs $$$ = over $100,000 At the end of the presentation we will collate all the criteria chart, along with other key elements into a decision matrix, you can use this to narrow your search for accumulation solutions. As an engineering firm, there are always room for exceptions to the rule, but our focus is on standard practices. Now….Mike is going to cover Conveyor Solutions
- Mike: Thanks, Jim. The first accumulation solution were going to cover is Conveyor Solutions. We’re going to cover everything from single file transport conveyor systems through highly controlled multi-lane conveyor systems.
- Mike: Tabletop Chain Conveyors: Single flow – one product wide, system. Accumulation occurs in the gaps between the products. Criteria: Handles many types of containers; rounds, non-rounds and packages sizes from small to case sizes. First in, First Out Simple Controls – Product backup detect sensors & motor control. Low Cost – Essentially just adding sensors & logic to existing motor controls.
- Mike: Drawing: This drawing shows a tabletop configuration with product flow from labelers to a case packer. Best location for accumulation is after the 180 curve upstream of the case packer. Additional accumulation can also be provided upstream of the 180 curve. Best Uses: Low cost accumulation since the conveyors also fill the need for transport. Products that need to maintain F I FO integrity, one product wide. Need a little buffering between equipment to smooth out timing issues. Pitfalls: Limited accumulation. Back pressure constraints may reduce the useable space. Accumulation in turns may be limited for non round containers and packages. Product clamps can increase useable accumulation space by reducing back pressure and protecting products at curves.
- Mike: The tabletop serpentine conveyor is also a single file accumulation solution. This solution increases the accumulation / buffering capacity by increasing the conveyor path. Criteria: Generally the same as tabletop conveyors All types of packages F I F O product sequence. Simple Controls – Backup detect sensors & motor control. Low Cost – Essentially just adding sensors & and few more motor controls.
- Mike: Layout Description: This layout shows the Serpentine Conveyor solution in place of the straight tabletop conveyors from the previous layout. By adding a longer conveyor in the serpentine design, buffering capabilities are doubled compared to the previous tabletop solution. To Recap Best Uses: A simple solution to increase capacity Use speed to create gaps. Motor controls help to relieve pressure. Clamps can be added for additional pressure relief and to protect products in turns. Pitfalls: Uses quite a bit of floor space for the accumulation it provides. Poor choice for products that can’t accumulate in turns. Additional drives are needed since there is more chain to pull, so some additional cost
- Mike: Serpentine Table: The photo shows a serpentine table that is still a “one product wide” accumulation solution, but is more compact than the previous serpentine conveyor solution. Criteria: Round and non-round products FIFO Simple controls – Just 2 drives and a single back up detect sensor. Low Cost: The photo above shows a Serpentine Table accumulating small vials which would be under $50,000 – one dollar sign.
- Mike: In this layout we have a cleaner supplying bottles or cans to a filler. Once the bottles have been filled, they need to maintain First In First Out integrity before heading on to the next process. The serpentine table applied here provides the needed buffering in a relative small foot print. Best Practices: FIFO Small footprint Typically only requires 2 motors & a back up sensor. Product back pressure is reduced due to the switch back turns. Pitfalls: Limited accumulation capacity as accumulation only occurs in gaps. Not well suited to high speed lines due to centrifugal force of product around the turn. Not always self clearing. Product may need the assistance of another product to transfer from chain to chain.
- Mike: Picture: In mass flow conveyor figurations you move from a single file configuration to multiple products wide, configuration. Criteria Both Round and Non-round containers Basically F I FO overall but some containers may skip others a little. Controls are fairly simple – Back up detection sensors and motor control. Low cost solution for how much accumulation. Best Practices: Dual purpose conveyor utility: mass flow accumulation and transport Effective use of floor space. Good accumulation solution that requires less product impact – decreases product damage Mass flow conveyors increase buffering capabilities compared to the previous conveyor options Pitfalls: Really needs to be a round or non round container May require secondary pieces of equipment to slow product down to mass flow speed and then take mass flow products back down to single flow.
- Mike: LBP chain conveyors – LBP stands for low back pressure Free Spinning rollers are integrated in the chain, many different chain types available including fine pitch for small packages and large pitch for cases. Criteria LBP chains handle rounds, non-rounds, packages F I F O Controls are simple Low Cost: LBP chain may cost more than regular tabletop but it is still a relatively low cost accumulation solution. Best Practices When longer runs of accumulation are required Very gentle handling of product, low product damage Dual duty - transport conveyors that also have accumulation benefits Also fewer drives are needed because longer runs are possible Large LBP or Roller Top Advantages Compared to Roller Case Handling Conveyor Modular belting provides easy maintenance Quieter operation than roller systems Longer life – less maintenance Pitfalls Some products are unstable on the integrated roller type chain Side transfers are problematic on this type of chain
- Mike: Zero Pressure Lift: This piece of equipment is designed to lift individual products or groups of product off the chain. It is possible to zone an entire conveyor length, including turns. Criteria: Package handling, trays, cartons, cardboard over-wrapped products F I F O Complex controls – Involves sensors and Pneumatic lift controls for each zone. Low to Mid range cost: Longer systems would be in the 2 dollar sign range, due to the additional controls cost and engineering the lift zones specific to the application. Best Practices The is best used for a product that cannot handle impact, like an open tray where spillage is a concern Reduces packaging scuffing damage Dual Utility Conveyor for transport and accumulation. Pitfalls The solution offers limited accumulation, you can only accumulate by closing the gaps.
- Mike: Next we will talk about Multi-lanes systems. This is an eight lane multi-lane accumulator with small roller LBP chain. Gates and merge zones are used to deliver product to and from the lanes. Criteria: Although multi lane accumulator can handle most products, this one is engineered for package handling. F I FO product sequencing. The controls are complex: with gating at the infeed and escapements at the discharge. The chain cost, controls cost take it into the $$ (2 dollar sign) range Best Practices Much more accumulation than linear conveyor for the size of the footprint Again, the roller LBP chain offers low back pressure resulting in less product damage Packages traveling narrow edge leading often do not require gating at the discharge end Pitfalls Changeover between products can be cumbersome. Generally used for products or packages of similar width. Adjustment ranges of +/- 1.0”
- Mike: This is another example of multi-lane conveyors designed for round and non round packages. This unit requires gating at the infeed and discharge for product stability. Criteria: Round and non-round bottles including PET containers. F I F O – product sequencing. The controls are simple to moderate: due to the escapements at the discharge end. The cost will most likely be on the low end of the middle range.
- Mike: This is a layout of the gated multi-lane system designed to handle PET bottles This example was used downstream of a blow molder to ensure there was ample room to allow the molder to purge all in-process products. We have highlighted the swing gate in blue in the blow-up as you can see on the slide. For unstable products such as bottles, gates would be required at both the infeed and discharge ends. Best Practices: Round and non-round bottles Vacuum can be added to this solution to stabilize empty PET bottles. Again, a high density accumulation solution for a reasonable sized footprint Although not shown in the drawing, this configuration can also incorporate turns. Pitfalls: Similar to the previous multi-lane conveyor for package handling. Generally used for products or packages of similar width. Adjustment ranges of +/- 1.0”
- If you’re using a tabletop or serpentine conveyors to accumulate, what can you do to relieve back pressure? LBP chain, clamps, additional drives, zero pressure lift zones. Are conveyor accumulation solutions limited if you have a sanitary room environment? No. With the exception of LBP chain, all solutions discussed for standard table top chain would apply in sanitary environments. Spacers may need to be added between flat surfaces for clamp mounting to facilitate cleaning. Does a conveyor solution for accumulation typically cost less than a machine solution? Yes, The reasoning is that there is going to be a need for transport conveyors between equipment anyway, which represents the bulk of cost. Simply adding some controls and perhaps some additional conveyor length is typically lowest cost solution. The tradeoff is that the amount of accumulation is limited to the open spaces or gaps between the products.
- Jim, EQUIPMENT SOLUTIONS Now we’ll talk about the typical machine accumulator solutions that are mostly used by manufacturers of food products and consumer packaged products.
- Jim: This is a commonly used accumulator – a re-circulating table. Criteria Handles round and non-round containers Products come out of the accumulator randomly – some packages may stay on the table for a while before coming out The controls are very simple; it only requires table-full status And it is a low cost machine solution
- Jim: Basic principles of operation – Products are normally transported through the center as you can see in the drawing. There are two wide belts on each side of the “main transport” conveyor belt in RED. One belt travels in the direction of the main belt and one travels in the opposite direction. During a downstream blockage the products backup into the recirculation table, and by back pressure flow onto the reverse flowing wide belt. The products flow to the opposite end of the conveyor and are diverted back onto the main transport belt. If the discharge is still blocked then the products will continue re-circulating until the table reaches the full state ( which is 75-80% full)
- Jim, Some variations of the recirculation concept is the loop accumulation table. The key feature of this unit is it eliminates the abrupt change of direction at the turn around point.
- Jim: The re-circulating accumulation table can also handle a reverse tapered container, like a yogurt container or a frozen dessert topping container. But in this case, the re-circulating table needs to have a cover designed into the solution to prevent containers from shingling. Best Practices: For round and non-round containers that need accumulation and single filing and fairly slow speeds under 200 CPM As I mentioned, with a cover, it can handle tapered containers. It is fairly compact and self clearing Pitfalls: The table can’t be loaded past 75% - 80%. If we fill the unit to a greater density we lose the free flowing action of the table. When considering a recirculation table you may see an uneven discharge flow of product, as the combining action is not even. Also there maybe a lag as the products need to travel down and back before they are discharge. We normally recommend a transfer down stream of the unit, if product needs to be back to back, such as when feeding a filler or labeler. Containers need to be stable when reversing direction. Transfer downstream Containers need to have a stable foot print so they don’t tip when reversing direction –a tall aerosol can for example.
- Mike: This picture shows a typical Bi-Di Table. Sensors on the run by conveyor detect backup and the table's belt moves at a right angle away from the conveyor line to load the table en mass. The table pauses when the back up is relieved. The same sensors determine when the blockage is cleared and then the table automatically reverses the belt to unload the table back onto the conveyor line. Criteria: Round and nearly-round containers Product sequence is randomly to F I L O Controls are simple - proximity sensors & motor control Low cost equipment solution
- Mike: Returning to an earlier layout, this time we are looking at the Bi-Di table feeding product to a “Filler”. The Bi-Di table was chosen here since FIFO control was not required prior to the filler. As mentioned in our previous webinar, “Mistakes to Avoid with Accumulation layouts” there needs to be sufficient width of conveyor feeding the table to prevent product bridging. The previous webinar is archived through Food Engineering with a link on our website Best Uses For round or non-round containers Provides a lot of accumulation in a comparatively small footprint. Self clearing – a sweep bar takes all the products off – including the transfer-plate. Products are normally single filed downstream of the accumulation table Pitfalls Not an accumulation solution for unstable products or products that can’t be single filed Products need to be relatively stable as they transfer on and of the Bi-Di table The table does not always completely fill – 90% efficient is typical.
- Jim: One of the more dynamic types of variable length accumulators is the Flex Flow Accumulator. Criteria: It handles may types of containers and packages, like stand-up pouches, ovals, rounds Exact First-in, First-Out The controls are complex – we need to sense product movement on the line both downstream and upstream It a solution that will cost between $50K and $100K for most consumable packaging
- JIM: The variable length accumulator operates on the concept of an expandable travel path which automatically changes length to match fluctuations in production.
- JIM: Another photo showing the path expanding from the previous slide.
- JIM: This drawing shows the carriage during normal operation. Products travel normally through the serpentine style path. The light blue shows the path going through the empty unit.
- JIM: Then in the events of a downstream production stoppage, this moveable carriage assembly increases the travel length, and therefore the accumulation of the product in the machine. The light blue in this drawing shows the carriage when the accumulator is running full.
- Jim: Side transfer is required at two points, at the in-feed and at the discharge. At all other corners the product is driven around the radius. Product is carried on one continuous crescent style chain. Best Use Cases When FIFO accumulation is critical The in-line accumulation delivers a more consistent product flow to downstream equipment – no lead or lag time to restage infeed and discharge Often good accumulation solution for products typically hard to handle; because it has almost non-existent back pressure and also has a crescent style chain that travels around a disc that prevents wedging of product Infeed and discharge at different speeds Pitfalls The Flex Flow Accumulator has a large footprint The initial cost is higher; the variable length mechanism is expensive For it’s size, the accumulation time is a few minutes; basically it is still a single path Recognize the centrifical force exerted on the product going around the small disc as high speeds
- Jim: This is another type is variable length accumulator. It also automatically expands it’s usable length. This unit is also first-in, first-out and pressureless. It uses a stacked concept.
- Mike: The next accumulation machine is the Alpine Accumulator which is available in either an elevator or a lowerator configuration. Criteria: As long as the products are stable, it can handle round, non-round containers and packages. It is F I F O The controls are simple - back-up sensing, motor controls and clamps And it is a fairly low cost accumulation solution
- Mike: The Alpine accumulator can be designed to convey products up and down, or up and over or convey products in one direction. This layout is an example of two accumulators that allow for a fork truck aisle. Best Use Cases: The Alpine is best utilized when versatility is needed. For compact floor-print requirements; makes excellent use of vertical space Conveying between floors In-line processing for heating and cooling Dual Purpose: Overhead conveying to open up floor space Pitfalls: The product must be able to convey on a slight incline; taller unstable products may not work on an Alpine. Some non-round packages may required extra controls to navigate the curves Capacity is limited to closing the gaps
- Jim: The vertical accumulator uses specially designed flights to store the product. The accumulation time is determined by the height of the unit and flight length Criteria: The accumulator works well with cartons, square or rectangular shaped products It is First In – Last Out – or random The controls are complex; A stop device is required to stop and ready the rows of product before indexing and allows rows to be introduced Depending on the application the cost can be over $100,000.
- Jim: This drawing shows a dual flight – chain lift model of the Vertical Accumulator. During normal operation, the product passes through the accumulator. When a downstream malfunction occurs, the accumulator will INDEX UP rows of products until the accumulator is full or until downstream production resumes. At that time, the accumulator will reverse and deposit rows of product back onto the transportation conveyor. The configuration is used for heavier products.
- Jim: This drawing shows a single – flight, side-load model for the vertical accumulator. On the side load configuration, pushers are utilized for the in-feed and the discharge. Depending on the product and carrier design, it may be possible to use both sides of the accumulator for storage. Both of the vertical accumulators can be used either in-line or off-line. This configuration is used for lighter weight products.
- Jim: Here is a typical layout using the Vertical Accumulator in-line. Best Cases Uses: Minimal product damage It is stationary during accumulation When orientation needs to be maintained Can be a high volume machine, 13 - 14 indexes per minute Small floor print compared to the volume of vertical accumulation Pitfalls: Understanding of the in-feed and discharge conveyors; requires sequencing conveyor Need available Ceiling height First In Last Out Product needs to be stable enough to back – up and maintain stability on the flight Cannot load and unload at the same time.
- Jim: While not a commonly used accumulator, the square box accumulator is worth a mention here because it uses the indexing row concept on a uni-directional table. Criteria: It handles square or rectangular shaped products or packages It is FIFO The controls are complex (sensing row logic, lift and motion) The cost is usually in the $$$ category
- Jim: The concept is to back up rows of products and push them onto a wide moving belt located at a right angle to the infeed. Rows of products are conveyed through the table where each row is lifted up to separate it from up-stream rows. The lifted/separated row of products is pushed onto the discharge conveyor. During a downstream blockage, the rows of product are backed up and stored on the accumulation belt. The length and width of the accumulation belt determine the storage capacity of the unit. Best Use Cases: The #1 reason to use this table is that it is a FIFO Commonly used coming out of the freezer where the product needs to retain its order It also has the ability for different discharge conveyor configurations. Infeed and discharge at different rates Pitfalls: The footprint can be large even for an average sized carton or product.
- Mike: These next group of accumulators belong in the high capacity category. In particular we are going to review the Rolco Serpentine Accumulator, which is a variable path accumulator. Criteria: The Serpentine accumulator is very versatile in the products and shapes it can accumulate. Carrier types may change, but these accumulators have been designed for round, non-round, containers and cartons. It has accumulated tissue logs in the paper industry. The products are accumulated FIFO or FILO depending on the configuration The controls are complex – sense upstream and downstream production The cost is in the (over $100K) category Operation Description: Product is transferred onto a product carrier. Carriers are progressed through the system from infeed to discharge. As the unit fills, the Uni-Slide descends, providing empty carries to the infeed and storage capacity for the filled carriers. As the unit discharges carriers, the Uni-Slide moves back up. Since the infeed and discharge operations are separate, the discharge can operate at a different rate than the in-feed.
- Mike: The next few slides show the concept of the Uni-Slide circled in red. Here the slide is in the empty position, very near the top.
- Mike Watch the Uni-slide move down as the product starts to fill the accumulator. Here the unit is about half full. This is the variable path concept of these high capacity Rolco units.
- Mike: This slide shows the Uni-Slide in the almost full position. Hopefully you get the idea of the expandable product path in these vertical machine solutions. There is a animated graphic as well as movies on the website that is better shows the concept for this machine at www.rolcoint.com .
- Mike: As noted earlier, Rolco units can be either FIFO or Filo. This is an example of a First In First Out Rolco serpentine accumulator with a bypass. The arrows show the normal direction of the product path. The by-pass, shown in grey, allowed for special products that could not be accumulated.
- Mike: This example is a F I L O unit used pre-store cases. It was used to ensure a steady supply of cases to a case packer during case erector stoppages. The grey path outlines normal case flow. The other line shows the supplemental case flow Best Uses: In high volume, high capacity accumulation requirements. Special product types from cases, paper towels logs. Storage and retrieval for product carrier pucks. Some systems have upwards 30,000 pucks. Where floor space is limited, but vertical space is available. Pitfalls: Product stability Product needs to be backed up somewhat at infeed. Carriers are loaded in slugs Footprint can be large
- Mike: This is a multi-level accumulator, which uses multi-levels of wide mat style conveyors. This unit is typically used to store cartons or boxes while the bottles that came in the boxes are being filled Multiple cases types can be stored separately. This style works well when different products are needed to be stored for collation. Criteria: Cases FIFO per layer. Complex Controls. The cost is over $100K Same overall advantages and pitfalls as the Rolco serpentine unit.
- Jim: We have a decision matrix to go over; and we’ll start with a sample application.
- Jim: The matrix basically gives a black circle to the criteria that it falls under. The criteria that we’ve selected that will help to narrow down your research for the right accumulator is: Type of Product Sequence – FIFO FILO or random Initial Cost Controls Footprint Capacity We’ll be sure to email everyone a link to this matrix, so you can see it more easily.
- Jim: Here is an application example: Package of cookies, cannot be backed-up FIFO for lot integrity At least 2 minutes of accumulation Must sense production fluctuations Space is not an issue
- Jim: The package is the most defining criteria in this example. Highlighted in blue are the types of conveyors and equipment that can be designed for a package. The list is narrowed to: Tabletop, Serpentine conveyor, zero pressure accumulation, multi-lane conveyors. As far as machines go, we have Flex Flow, Alpine, Vertical Accumulator and the Rolco Accumulators.
- Jim: Since we have a stand up pouch, we need to make another round of selection for just the solutions that can be designed to handle a stand-up pouch. The tabletop, serpentine, flex flow and alpine can handle stand up packages as long as they are stable.
- Jim: A stand-up pouch in this example, containing cookies cannot handle back pressure for accumulation. So, we need to further eliminate options that use back pressure such as the tabletop, serpentine and alpine. This leads us to the Flex Flow Accumulator.
- Jim: The other criteria fits for the application. It is a FIFO solution (for maintaining lot tracking) The cost fits the budget The complex controls read fluxes in production so the product accumulation path can expand without the need for back pressure The capacity will fill the need for two minutes of accumulation.
- Jim: You can visit our website at nercon.com and see video of all the accumulation equipment that we talked about in this presentation. All attendees will receive our new white paper called the “Accumulation Solutions” and the decision matrix download. And we have links to this webinar and our previous webinar on our website www.nercon.com. Now we are going to wind up the presentation portion and answer questions that you can type in.