In an effort to increase efficiency and reduce costs, our client contacted POWER to assist in the replacement of several conveyors and the installation of a new automation system for a ketchup bottling line. Our team provided detailed design for the conveying, packaging, and automation systems and equipment. We also supported our client by purchasing equipment, conducting Factory Acceptance Tests, and arranging shipping from the North American manufacturer.
This project decreased number of downed bottles on the line through improved transitions and controls, allowing the client to reduce staffing by two people per shift (for 24 hour, three shift, five day a week production). It also integrated a new bi-directional accumulation table to feed the existing labeler. The new accumulation table and upgraded controls and transitions reduced the need for manual supervision of the line. All the new conveyors on this line are controlled by a single new Allen Bradley ControlLogix PLC with new starters/VFDs.