Featured Machines

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• We are all aware of smaller size containers being produced. When that happens, there can be many implications throughout the production line. One such a case came to us from a major cereal producer who had downsized the fill but needed to keep the store facing space. Once the cases were filled with cartons, the footprint to height ratio made the case unstable on its own. With a long distance from the case packer to the palletizer, ups, downs and turns caused the cases to tip over and stop the line.

  The solution in the customers mind was to combine multiple cases together creating a bundle that could travel in a stable condition. With pallet patterns being different for different SKU's, they asked about combining cases in groups of 2 or 3 and allow pass-through capability for more stable cases. In testing, they discovered they could glue cases together with an adhesive that would hold the cases through transport, be palletized and stretch wrapped. 24 hours later, the adhesive would dissolve, and all the cases would be singles again, ready for distribution.

  The Emerald team brainstormed with the customer to develop a methodology that would outpace the capability of the case packer. Unlike typical adhesive that sets in less than a second, we needed about 2.5 seconds of compression for this formula.

  The Combiner accepts up to 16 cases per minute, allowing the first case into the compression, moved out of the way to allow a second case to have adhesive applied and combined with the first with dual servo controlled overhead compression plates. A third case is released, glued and combined with the first two. The bundle is released to a rotator section where the bundle is turned 90° either clockwise or counterclockwise.

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  A fulfillment company came to Emerald Automation to find a machine that would load bags of various products into standard RSC cases. As a FANUC Authorized Integrator, we offered a solution to use a robot with a spatula as an end effector.

  After accepting filled and sealed bags, we grabbed the completed bag and laid it down on a bag checkweigher infeed. The bag is then checked for proper weight and transferred onto an incline conveyor up to the robot tool. When the bag reaches the top of the conveyor, the bag is deposited onto the spatula tool. With the bag in place, the Robot moves, inserting the end arm and tool into the box, tilting the tool to leave the bag flat at one end of the case. On the next bag, the robot places the bag at the other end of the case, creating a 2 x 1 layer pattern. The process continues until the proper bag count is achieved. Depending on the order, they can load as little as 10 or up to 42 bags per case.

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  With more and more focus being put on Sanitary Designs for food production facilities, Emerald responded by changing our Dash-DP wash-down design to eliminate tubular frames and moved to an open design to eliminate the opportunity for bacteria to settle and collect in tight locations where chemicals and water can't get. The formed Stainless Plates and standoffs leave plenty of room to apply cleaning chemicals and water to rinse the machines. We even upgraded the electrical components to stainless construction, eliminating the need to bag parts of the packer or the whole packer during clean-up. This saves time for the operators to get the job done.

  
  

  Here at Emerald Automation, we listen to the needs of our customer to build machinery to live in their "real world" environment. We didn't just take the existing design and make it somewhat wash-down, we started with a clean sheet. If you have a need for a sanitary design casepacker, give us a call or email us at sales@emeraldautomation.com.

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  A customer came to Emerald needing a Bulk Product Case Packer (Dash-BP). They also required Lane Product Infeed Guides for existing Product Conveyor with transition to Loader Infeed. Other requirements included: A hinged Pass Through Conveyor (for access). The ability to merge onto Loader Laned Variable Speed Infeed Conveyors. An Acceleration Belt for product separation. Product counting by lane. Polycarbonate Guard Packaging with Safety Interlock.

  Emerald was able to fulfill all the customers requirements for packing the product and integrating multiple conveyors and existing equipment into a seamless operation. Our Design Engineers are able to custom build every machine to the specific requirements of every customer. Our System Integrators are able to integrate our products into any existing system.

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  This system was designed and built to flip sealed cases, around a horizontal axis, to the proper orientation for the next machine in the production line. It should be used on Automated Packaging Lines that utilize existing live roller style conveyors. This system is able to be pulled in/out of service rapidly. Capable of flipping 8-10 boxes per minute (Higher rates can be achieved. Please call for detailed information.)

  Emerald was able to fulfill all the customers requirements for packing the product and integrating multiple conveyors and existing equipment into a seamless operation. Our Design Engineers are able to custom build every machine to the specific requirements of every customer. Our System Integrators are able to integrate our products into any existing system.

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