Cutting-Edge Box Handling Automation

Project Overview

CHL Systems successfully designed and implemented a comprehensive automation solution for a prominent poultry producer, revolutionizing their case and tote handling processes. This project showcased Our expertise in integrating advanced conveyor systems and sorting technologies to enhance operational efficiency and product handling.

Key Challenges

  • Handling two patty sizes: 2 oz. (6 stacks of 14 tall) and 4 oz. (6 stacks of 8 tall)
  • Managing high-speed production rates of 6.25–6.28 slugs per minute from each forming machine
  • Merging patty slugs from multiple lines onto a single conveyor system
  • Ensuring smooth transitions between conveyors to maintain patty integrity
  • Integrating with existing equipment and meeting specific height requirements
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CHL Systems’ Solution

CHL Systems designed, built, and installed a cutting-edge box handling system to deliver empty cases/totes to production and transport
full cases/totes to end-of-line processes. Key features of the system include:

Innovative Conveyor System Design

  • Designed and installed over 3,700 linear feet of conveyor systems
  • Implemented a dual-purpose system for handling both empty case/tote delivery and full case/tote takeaway
  • Utilized modular bolt-together construction for overhead conveyors and welded construction for floor-mounted conveyors
  • Implemented a return loop to deliver unused cases/totes back to case erection room for reintroduction

Advanced Sorting Technology

  • Integrated multiple Intralox DARB Sorter S4500 units for high-precision sorting
  • Leveraged the sorter’s Dual-Stacked Angled Roller Belt technology for gentle 90-degree product transfers
  • Implemented pneumatic actuation systems for precise control and reduced product damage

Vertical Transport Solution

  • Incorporated two AmbaFlex SpiralVeyor SV-Series units for efficient elevation changes
  • Optimized floor space utilization while ensuring smooth product flow between processing levels

Customized Control System

  • Developed a comprehensive control system featuring Allen-Bradley ControlLogix and safety processors
  • Implemented a user-friendly HMI with a 12-inch touchscreen for intuitive system management
  • Integrated barcode readers and photo eyes for accurate product tracking and sorting

The CHL Systems Advantage

This project exemplifies CHL Systems’ ability to deliver tailored automation solutions that address complex challenges in the food processing industry. By leveraging cutting-edge technologies and applying our deep industry expertise, we helped our client achieve significant improvements in efficiency, flexibility, and overall production capabilities.

Increased Throughput:

The system handles up to 60 cases per minute, with an average rate of 40 cases per minute, significantly boosting production capacity.

Improved Product Handling:

The Intralox DARB Sorter S4500 ensures gentle handling of products, reducing potential damage and maintaining product integrity.

Seamless Integration:

CHL Systems successfully integrated advanced conveyance technologies with production and end-of-line processes, ensuring a cohesive and efficient production line.

Cutting-edge Sustainability:

The system delivers empty cases/totes only when called upon for inventory needed and returns unused packaging products to be reintroduced.

Enhanced Flexibility

The solution accommodates various product types and packaging formats, including split breasts, wings, and whole birds.

Space Optimization:

The AmbaFlex SpiralVeyor SV-Series enables efficient vertical transport, maximizing the use of available floor space.

Future-Ready Design:

The modular nature of the system allows for easy expansion and adaptation to future production needs.

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