Keeping Things Moving: Upgrade Your Automation System with Conveyors
One of the most significant advantages of automating, or even partially automating a process, is the time saved by allowing workers to focus on more than one task or eliminating the need for human workers altogether. An uninterrupted process is a significant factor in successful production. From simple to complex automation systems, conveyors keep things moving within the system and in some cases even extend the system’s capacity and runtimes. A conveyor can be a silent hero of a system but the wrong conveyor can be an obtrusive nuisance that needs constant attention and upkeep.
It could be time to upgrade or replace your conveyor if:
- It requires more maintenance than normal
- Certain sections of the system consistently have problems
- Products are coming out of the system damaged
- You’ve changed your products or capacity needs
Choosing the Right Conveyor
A company’s product shapes the automation system; everything from the size, shape, texture, fragility, and more needs to be factored into the creation of an automation system. In the end, delivering a high-quality product to customers is the top priority for any company. The automation system should be built to fit the application, not the other way around.
There are many things to consider when buying a new conveyor or replacing an existing one:
- What is your product?
- What are your size requirements?
- What is your application?
- What is your budget?
There are multiple types of conveyors available to fit your specific application and system. Finding the right one can be the difference between a smooth process and a lifetime of troubleshooting and maintenance. While it’s best to be informed about the different types of conveyors, our automation experts can help you choose the best conveyor for your application.
Types of Conveyors
Vacuum Track Conveyor
The Vacuum Track Conveyor (VTC) is a standard option. Using suction force, the VTC controls products as they move down the conveyor. Even irregularly shaped products are easy to control when they are spread out flat on a horizontal surface. Vacuum track conveyors have multiple configurations to fit different applications. The open surface and linear mounting bars provide quick mounting and access for optional components, such as inkjet or laser coders, scanners, vision systems, and more.
High-speed tipping is the ideal application to use the vacuum track conveyor. Tipping is a common automation term describing when you take two products and join them together with one product (tipping product) on top of another product (base product). Glue or other kinds of adhesive are used to keep the two products together. Tipping requires an open surface for access to the base product and mounting the friction feeder over the top to dispense the tipping product. The vacuum track conveyor offers precise control of the base product that is needed for accurate tipping.
Shingling Conveyor
The Shingling Conveyor accumulates batches of products for convenient operator removal. Usually found at the end of a system, the processed products on the Shingling Conveyor do not need immediate attention, adding capacity to the system and extending the run times. The shingling conveyor moves at a slower rate than the rest of the system, causing the products to shingle and stack up on the conveyor.
Batching flat products, such as booklets, brochures, and or even filled pouches, is a common application for the shingling conveyor. These batches can be queued up for removal or to be transported to the next step of the system. The spacing of the shingled products can be easily adjusted by changing the speed of the conveyor.
High-Speed Collator
The High-Speed Collator (HSC) is an open-face conveyor that utilizes lugs to handle firmly, control, and transport products down a conveyor. Products automatically transfer onto a belted takeaway and the lugs can be spaced and timed to match a downstream transport. The HSC has an open surface, making it ideal for mounting components, such as barcode scanners and vision systems, over the conveyor.
The lugs of the HSC lend themselves incredibly well to the application of stacking and batching. The High-Speed Collator System uses friction feeders to feed different types of product into a drop table to form a stack that is dropped onto the conveyor. The lugs move the stack to the next friction feeder for the Drop Table to add to the stack. The collation of papers is moved to the next step of the system with the lugs keeping the stack square.
Automatic Product Loader (APL)
The Automatic Product Loader (APL) is a special conveyor that extends a friction feeder’s production capacity and, in turn, the system’s run times. Designed specifically for MFT Friction Feeders and their automation systems, products are spread horizontally over the APL’s surface instead of stacked vertically in the feeder. This method of loading the product is perfect for irregularly shaped products and increases the capacity of the friction feeder.
Irregularly shaped products have problems stacking vertically in the friction feeder. The APL is ideal for these irregularly shaped products. For example, plastic bags with a zipper do not stack well vertically. The zipper makes the stack uneven, which leads to jams and skewed products coming through the friction feeder. The APL has the product spread horizontally on the conveyor that feeds into the friction feeder eliminating the need for a stack. Even standard products benefit from an APL as they can easily be loaded onto the APL to expand the friction feeder’s capacity and seamlessly extend the run times of the system.
Integrating and Installing Conveyors
Integrating and installing conveyors is the easiest part of the process. Especially if you have experienced and knowledgeable workers helping you! MFT Automation is a one-stop shop for conveyors and automation systems. We work with customers from the first design plans to integration and installation. We have a dedicated team of mechanical engineers and technicians that integrate, test, and fine-tune your systems before installation. We offer on-site installation and training so that everyone is on the same page regarding the automation system. After installation, we have a dedicated aftermarket support team that provides technical phone support, and field service support for troubleshooting, repairs, and more.
MFT Automation
MFT Automation has been helping customers design, build, and integrate high-performance automation solutions for over 25 years. MFT Automation’s equipment, systems, and services are known for their flexibility, accuracy, and performance. Our success is made possible by our engineering-oriented and customer-driven approach to finding the best possible automation solution for customers’ applications. With an abundance of in-house resources including Mechanical Engineering, Electrical Engineering, Software Engineering, and a machine shop with modern CNC and lathe machine tools, we work with customers from the first solution draft to installation and integration. Contact us with your latest automation challenge, online or call us at 1-651-427-1264.
How to Automate Your Pouch Packaging Process
In many industries, heat-sealed pouches have become an efficient and cost-effective way to send product samples, and sometimes even products themselves to customers. Heat-sealed packets are highly versatile as they can be made with many different materials and come in many different sizes. Because of their versatility, they are used in many industries for many different kinds of products. And a new demand for custom samples and products has risen in consumers that make re-sealable and disposable pouches as a good way to fulfill lot size one orders for small items. The small and portable pouches are also perfect for the current grab n’ go culture. Anything from snacks to beauty creams to medicine, the pouches can hold a little bit of everything and fit easily inside bags. Looking to start using heat-sealed sample packets or looking to automate your pouch packaging process? From verifying barcodes to labeling pouches, there are many opportunities for automation. Here’s our guide on automating your pouch packaging process.
What you Need to Know about Tax Stamp Application
In order to understand tax stamps and the process for ensuring secure and safe tax stamp application, there are a few components you must first understand. In this blog we’ll cover what a tax stamp is and what makes it different from other consumer stamps. We’ll also share common industries who may use tax stamps and identify automation equipment that could increase your packaging efficiencies.
3 Techniques for Successful Automatic Label Application
If you’re looking to learn more about proven labeling techniques for automatic labeling and what’s needed for your label applicators, this blog is a great place to start. While there are many techniques in the industry, wipe-on labeling, tamp label applicators, and blow-on labels are three techniques we recommend for successful automatic labeling. Let’s dive into each technique with a bit more detail.
1. Wipe-on Label Applicator
Sometimes referred to as “merge” labeling; wipe-on labeling is where a label is dispensed in the same direction of flow as a product when a label is being applied. This is an automatic labeling technique that is widely used in the industry but requires precise set-up for optimal production speeds and quality output. It is also used for products with irregular shapes and surfaces that are not flat (source).
Wipe-on label applicators typically require the base product to be moving and consistently presented to the labeler. While the product moves towards the labeler, a free rotating roller or brush is used to aid the transfer of the label onto the moving product. From there an encoder can be used to track the speed of the product the label will be applied to so the labeler can apply accurately if the product speed might vary.
For this technique to be successful, your automatic labeler should have either a single axis or multiple axis motor. A single motor will assist with unwind, rewind, and drive; however, it will likely require clutching mechanisms for the unwind and rewind functionality. Whereas a multiple axis motor separately powers the unwind, rewind, and drive.
High-Speed Applications
For wipe-on labeling applications requiring higher speeds, a vacuum box or powered unwind may be implemented. (See the third technique to learn more about vacuum/blow boxes and blow-on labeling.) To meet these high-speed and tight accuracy requirements, a second stage may be added to the labeler such as:
Vacuum belt with motor drive: this option allows the label to be dispensed with the adhesive open (non-adhesive side facing the vacuum belt). The vacuum belt can then adjust position or speed to accurately apply the label such as using Multifeeder’s Accutipping controls.
Driven rotary vacuum wheel: this can transfer the label from the labeler to the product in a second stage for added speed or accuracy, similarly using servo controls such as Multifeeder’s Accutipping controls.
2. Tamp Label Applicator
A tamp applicator is a contactless technique for applying smaller labels on products. It is most commonly used on print and apply labelers; however, this technique can also be used on wipe-on label applicators for 3D products or hard-to-reach label placements (i.e. recessed areas). MFT 150pa Print and Apply Automatic Label Applicator
Tamp labelers place the label onto an air cylinder tamp pad or vacuum tamp pad before placing the label onto the product. As the product moves down the conveyor, a pressure sensor (such as Multifeeder design) can be used to indicate if the tamp pad comes into contact with the product. This is especially valuable for variable height products or more intricate products. Such products may also benefit from a complex tamp pad that can place a corner label on more than one surface.
To support a complex tamp pad, a second air cylinder or a hinge (spring-loaded or gas shock) may be required for the second side. A pneumatic style smart tamp or heavy-duty smart tamp could also be used to prevent any tweaking or sensitivity to dirt; learn more about the smart tamp we use in the MFT 150pa Print and Apply Automatic Label Applicator. Additionally, a tamp pad may feature vacuum to hold the label while an airblast is used to release the label onto the product.
3. Blow-on Label Applicator
This sophisticated technique is sometimes used to replace the industry-favorite wipe-on labeling; although it is slightly less precise. Blow-on label applicators use a controlled blast of compressed air to place labels at high application rates. (source 1, source 2). This technique is commonly used for blow labels on coupons and other high-speed applications that require a contactless application (i.e. glass or other fragile products).
A blow box or vacuum box can be used in a similar way when paired with a wipe-on labeler. Oftentimes the vacuum/blow box uses a muffin fan to create a vacuum effect by holding the label to the bottom surface of the transfer device. The wipe-on labeler will index the label onto the bottom surface of the vacuum/blow box, which is then held in place by vacuum. When a product traveling below the box gets to the location the label is to be applied, an air blast releases the label onto the product below. This feature allows the labeler to be placed either in-line or perpendicular to the base product flow depending on label orientation requirements.
Defining which automatic labeling technique is best for your product or application can depend on a series of variables. If you’re interested in learning more about these techniques and other labeling solutions for your product, we’re happy to help. Get in touch with one of our automation and labeling experts by contacting us here or check out some of our labelers here.
Send samples of your labels and base product to us for a complimentary evaluation and test video. Click the button below to get started.
Tags: Labelers, Integrated Systems
How To Expedite Your PPE & Medical Packaging
The coronavirus (COVID-19) has changed our way of life in 2020 — both personally and professionally. Employees are adapting to work from home policies. People are adding facemasks to their wardrobe. Companies are changing the way they do business. There’s a lot that’s changed.
For companies who manufacture and package medical supplies — we applaud you. These last six months have pushed you to adapt and accelerate production, helping millions of Americans stay safe. But the pandemic isn’t over yet. Hospitals across the U.S. are still struggling to keep people on the front lines safe. And, the need for PPE and COVID-19 medical supplies still remains a necessity.
Together, manufacturers and equipment providers can create more of these products. One of the first steps to doing this is to automate the packaging of PPE and medical products.
Boxes and Cartons for Automated PPE Packaging
- Facemasks
- Hand sanitizer
- Gloves
- Eye Protection/Gloves
COVID-19 Products for Automated Medical Packaging & PPE
- Test Strips (Automate packaging & batch counts)
- Test Kit Boxes and Cartons (Automate serialization & place UDIs)
- Disposable Thermometers (Automate packaging & batch counts)
- Manuals & Instructions
This blog is for those who already manufacture COVID-19 supplies, and those who want to start. If this sounds like something you’re interested, we’ve identified a few ways to help you jump in head first. If you’re already producing COVID PPE or supplies but need increased output, these apply to you as well.
How to expedite PPE & Medical Packaging Output
1. Use accurate serialization and UDI placement
“Serialization” and “unique device identification” aren’t foreign words to medical and pharmaceutical companies. These tools help safeguard products and track them throughout the entire supply chain. This is especially important for high demand products — like COVID PPE and medical supplies — that move fast. Automation equipment that supports serialization and UDI placement can help output acceleration. In turn, it could help provide medical facilities with more of the products they need during the pandemic.
2. Automate your batch counting and banding
During the pandemic, production line employees are (hopefully) following social distancing recommendations. Meaning, manual counting and preparation of products can take longer. This can cause some serious pains when your main goal is acceleration of product output. Automated equipment that batch counts and bands your products is a great solution. It offers limited human interaction and could offer some serious ROI right now.
3. Implement verification technologies into production
This step works hand-in-hand with step #1. Verification can be combined with serialization/UDI placement devices to create an airtight process for product traceability. Together they ensure the right product is being assigned the right code at the right time. Specific verification technologies that will help you accelerate your production include:
- Vision systems
- Barcode readers
- Rejection systems
Watch the video below to see some of these in action!
4. Invest in extra labeling machines and friction feeders
For obvious reasons, you’re likely experiencing high product demand. Hiring more employees, buying equipment, or upgrading existing equipment can help. But, we recommend focusing on options two and three.
Not sure if you need new equipment or can upgrade what you have? Talk with your automation equipment manufacturer or contact our team here.
A great place to start when evaluating equipment options is to start with what you have. Next, check your equipment’s cleaning and sanitizing options. With the pandemic still in full swing, there are regulations set by the CDC and FDA that must be upheld. To help meet these, we recommend looking into CIP automation equipment — also known as hygienic equipment. Below are a couple of hygienic options that could keep your company, products, and team safer.
Our PPE & Medical Packaging Equipment
Track & Trace System
for PPE & Medical Packaging
This system offers turnkey product handling for serialization coding, printing, inspection, and rejection. It also provides a trackable data file. Learn more about the Track & Trace system here or request a quote below.
Automatic Product Loader
for PPE & Medical Packaging
This machine multiples the product capacity of our MFT friction feeder systems by maximizing runtime and minimizing operators. Learn more about the Automatic Product Loader here or request a quote below.
Hygienic Labeler
for PPE & Medical Packaging
The Hygienic Labeler 300 meets IP69K requirements and meets and exceeds IP66/NEMA4X standards. Its Clean-in-Place design also provides minimal contamination points. Learn more about the Hygienic Labeler here or request a quote below.
Hygienic Friction Feeder
for PPE & Medical Packaging
This feeder is available in the 300 and 600. Both meet sanitary requirements and comply with IP66 or higher standards and NEMA4X standards.