Streamlined Success: Automation at the Heart of Growth

A once modest popcorn packaging operation faced a monumental shift. Acquired by a Fortune 100 company, the facility was set to become a cornerstone in the corporation’s expansion plans.

As the operation transitioned from an independent company to a vital piece in the extensive supply chain of its new parent company, orders skyrocketed, increasing tenfold almost overnight. The existing manual processes, once adequate for steady, predictable demand, became untenable. It was clear: substantial upgrades were necessary to keep up with the growing requirements.

Right Stuff Equipment (RSE), a renowned provider of advanced packaging automation solutions, stepped into the fray, tasked with transforming the facility into a state-of-the-art automated powerhouse. The heart of RSE’s strategy centered around conveyors supplied by Alba Manufacturing.

The newly installed system began with Alba’s pallet dispenser, which holds fifteen pallets in the magazine, feeding empty pallets onto a sophisticated conveyor network consisting of CDLR Conveyors, Drag Chain Conveyors, and CDLR Conveyors with 3-Strand Pop-Up Transfers. This network included ten special Thru-Drive-Side and Frame-to-Frame Transfers, meticulously engineered to handle the seamless transfer of empty pallets to the robot loading cells. Here, robots—five in total—spring into action, loading pallets with boxes that have been sealed and dispatched by RSE’s case tapers.

Once loaded, the full pallets journey down a pallet highway into an RSE supplied stretch wrapper, ensuring pallet integrity during transport. From there, the pallets are conveyed on a series of Chain Driven Live Roller (CDLR) Conveyors and Thru-Frame Transfers – before finally being picked up by forklifts and moved to the warehouse for storage.

The integration of six additional tight roller center CDLR Conveyors to depalletize cases of empty bottles from slipsheets for filling marked a significant enhancement in efficiency. This robot not only unloads the cases but also prepares the cases for the filling lines, thereby streamlining the process from start to finish.

This new system heralded a dramatic improvement in production capacity, jumping from handling four pallets per shift to an astonishing sixty. The benefits were multifaceted: not only did the automation reduce labor costs, but it also ramped up output significantly, allowing the facility to meet their new, increased demand.

The transformation was not just about meeting higher production numbers; it was about consistency, reliability, and precision in every packet of popcorn shipped. As the Fortune 100 company continued to push for excellence across its subsidiaries, the facility became a shining example of what could be achieved with the right investment in technology and innovation.

To see how Alba Manufacturing can help you with your robotic palletizing conveyance, please contact your local sales representative today or call us at 866.252.2634 or visit our website at www.albamfg.com.