Conveyors and Line Logic - Zane Hechter

Packaging Trainee
Checkout Assessment
Zane Hechter
Date: 31-Aug-2015

SABMiller 2014 Presentation information in footer

2
Purpose
o To move product from one point to another
o To allow for buffering between process areas
Transportation
o Bottles
o Cans
o Cases
o Crates
o Kegs
o Pallets

3
General
4
Types Category
o Slat chain o Mass / bulk
o Mat o Single Feed / reject
o Skate-wheel o Infeed / discharge
o Roller Direct Powered / Gravity Fed o Deceleration
o Belt o Acceleration
o Bulk Chain

5
General
Most common conveyor type
3.25, 4.5, 7.5
Uses
Mass, single file, reject, infeed,
discharge
Material
Stainless Steel
Plastic
PolyAcetal, XLF, HPP
Wear strip
Keep the form & keep slats in channel
SABMiller 2014 Presentation information in footer 6
Return Rollers & Catenary
Based on return roller spacing

Calculate catenary (intralox, regina, rexnord)
Calculate position of first return roller
Gap/distance between B 400 450 500 550

return rollers
Acceptable Cantery sag Y 50 75 100 125
Gap/distance between
last return roller & drive A = B x 1.5 600 675 750 825 Chain Return
sprocket
Serpentine
Rollers
Guide shoes
Guide Rail Height
Necessary for all conveying systems to ensure container control
Generally made of UHMWPE
Helps reduce wear on bottles (not great @ temp > 100C)
Should be designed to make contact on set points on bottle

Should not disrupt labels position on bottle friction rings
Should allow glass fragments to pass through lower guide rail
Lower Guide Rail After Labeller

Guide Rail Width
Single feed
Avoid container lock-up / avoid excess
scuffing / ensure smooth flow
5mm per side
Mass
Ensure effective nesting pattern / avoid
over-pressure

Bends
Transferring packages from one direction to
another
For use on horizontal conveyors
Use of a dead-plate imminent
Should be parabolic curve minimise
pressure build up avoid circular design

Used as an alternative to straight run
Provides smooth, continuous transfer through turns
More Expensive
More susceptible to brewery

specific damage
Requires guides to run along
Guides add additional side forces
Heavy dust / dirt can damage
system beyond repair

99% inherent efficiency 3-4 tracks 1.21m
High speed 1.21m
Access holes on both sides for cleaning 1.5m
Medium speed 960mm
180mm height adjustment Slow speed 710mm
Optimal height 1.4m Break in period 0.5-1% stretch

All contact surface UHMWPE Guide rails
Single SKU fixed
Plastic chains XLF polyacetyl
Multiples SKU toolless, repeatable settings
Length
Guards to ensure zero access to pinch-points
Empty 10m
Full 8m Plastic chains static dissipation by
Dissipation plate
Parallel transfer lengths
Rails / wearstrips
8-10 tracks 2.21m
Ionizer bars
5-7 tracks 1.71m
Other
13
General
Mass type conveyor with large surface
area coverage
66% - 95% coverage
Width 79 4496 mm
Uses
Empty Can depalletiser
Pasteuriser deck alternative to
walking beam
Material
Acetyl (low friction)
Stainless Steel
General
Low friction for sensitive products
Can be used as a low friction guide rail
for pressure combining
Helps prevent jams
Most Common Uses

Shrink wrapped packs
Boxed packs

General
Elevates product to another floor
Appropriate for single cans heavy trays &
cartons
Width 300 600 mm
Elevation 6.5 m / drive
Angle of Inclination 9

Can mix up various pieces
Plenums 300 3000 mm
Bends 15 90
Up / downslopes 5 15
Air to be filtered
Air-tightness control by air-tight flange connections
Full access to all sections allow for effective cleaning
Dry lube system to optimise CoF
Fan system VSD driven to accommodate different bottle sizes / shapes / weights

General use
Cases, trays, empty & full pallets
Assembly
Hex shaft, press fit bearings, Roller
Steel, aluminium, PVC, zinc-plated steel

Directly powered by chain or belt
Direct power by 24 VDC brushless motor
Make use of gravity
Slippage & accumulation possible

General use
As friction devices to convey product up and down inclines without slip
310 810 mm
Typical use 50 kg/m
Positively driven
Do not allow for accumulation
Due to frictional properties
Can handle a very wide range of products

General use
Long distance crate conveyor
Two or more chains in parallel

Not a wide range of product utilisation
Positively driven
Do not allow for accumulation

Lubrication
21
General
For slat-chain conveyor systems to reduce friction
and allow for slip
Advantages Disadvantages
Reduce wear between conveyor & wear strip Lube can wet & damage label
Reduce power demand on motors Can cause EBI rejects
Reduce line pressure by allowing for slip Cost
Reduce noise levels If biocidal properties not correct slime production
Assist with stability of moving bottles gentler acceleration

& deceleration
Cleaning & biocidal properties

Soap Lubricants Synthetic Lubricants
Based on fatty acids Long carbon chain amino molecules
CoF: 0.06 0.125 CoF: 0.12 0.18
Advantages Advantages
Relatively cheap Not sensitive to water hardness
Good lubrication properties good reduction in CoF Inherent biocidal properties
Strong surfactants good cleaning properties
Disadvantages
Requires softened water / sequestrants Disadvantages
Biocides must be carefully controlled to minimise Poor Lubrication vs Soap
bacterial growth More expensive than Soap
Requires regular cleaning (not necessarily a bad thing)

Volume
Plan the line
Locations of spray points
Amount required per spray point
l/min per nozzle
Create loop to equalise pressure over nozzles
Install drip trays
Water pressure 3.5 bar
Chain lube concentration 0.3 2%
CoF 0.13 after 3 minutes

Minimise water and lube usage with an aim to run conveyors completely dry.
Why
Reduce line water usage sustainability & cost saving initiative
Waste water treatment cost
Zero dripping on floors waste & safety
No drip tray less hardware
Hygiene no slime build-up
Minimised corrosion
Minimised false rejects at EBI
No water / foam on labels

SKF
Sprays a small amount of dry lube at high friction points on conveyor
Lubes does not leave conveyor surface
Central distribution system up to 200 lube points
How it works
Conveyor guides fitted with lubrication screws
Lubrication plates under slat-chain fitted with nozzles to apply lube
Drylube.co.uk
Beka-lube.com

Can be a huge source of downtime on the line
Must comply to Conveyor best practise constantly being
changed
Newer systems
Have spray points to connect a hose for direct cleaning
Ideal
Remove conveyor sections during weekly shut
Clean and scrub
Replace required parts
Lube all required points
Spray down other conveyors
Remove all glass and foreign objects
The Machine of the Conveyor World
28
Pressure Free Combiner
Replaced Pressure combiners
Pressureless combining from mass single feed
Some machines require single file infeed

EBI
Filler
Labeller
Principle
Speed differential
Gravity w/ reduced friction
Number of chains
Guide rail profile
Infeed configuration

Conveyor Purpose Speed
Pre-dosing Supply enough bottles to keep dosing conveyor full Higher than dosing conveyor for constant supply & maintain nesting
pattern
Dosing Determines distribution & flow of bottles to slip recovery No slip & minimal pressure while maintaining nesting pattern
Slip combining Allows controlled combining of bottles Based on flow from dosing conveyor
Slip recovery Balances bottle spacing while discharging bottles from combiner Variable according to control photocells based on gaps between
bottles removal speed calculated from bottle pitch

Speed Increase
Pre-dosing constant feed dosing
Dosing runs no-slip with optimised

nesting
Gravity and geared slat chains

increase speed toward single lane
All bottles in single file before

photocells
Photocells detect gaps on the single

file slip recovery
M03 constantly varying to balance

gaps & discharge at correct pitch
Speed of discharge based on

downstream machine pitch & rating

2 Basic variations in design

Effect of inclining a conveyor

Principles & Guidelines
34
Process
Management Brief
Sales forecast
Expected volume
Growth
Pack mix
Capacity profile
Conceptual Design
V-profiles
MER
Accumulation
Operator Utilisation
Detailed design

Efficiencies Ergonomics
Machine
Machines
Factory
Class of Product
Pack sizes Cleanability
Maintenance
Pack Changes
CapEx
Physical Footprint TCO
Upgrade-ability
Future Expansion
Conveyor speeds
Accumulation requirements

MTTR Mean Time to Repair Inherent efficiency
Average Time to fix a stoppage % machine run time from available run time
MTBF mean time between failures Dynamic accumulation

Average Time between stoppages Amount of time an up-/downstream machine can
TGNS Time to go back to normal situation stop without affecting the machine up-
Average Time taken to get back to normal /downstream from it.
operating conditions
Micro / macro stops Static accumulation

Sub-3 min / post-3 min stoppages Amount of time it would take to completely run
MER out a fully charged conveyor at rated speed
Average throughput of machine given its failure
characteristic & inherent efficiency
Flash / Sterile Lines
Warmer replaces the Pasteuriser as the bottle of the V
If the warmer is not required The SBT is the bottom of the V with
the filler maintaining 30% SBT volume
If SBT Volume > 30% Filler ramps to 110% LR
If SBT Volume < 30% Filler ramps down

Principle: Accumulation
Designing with a V-Profile essentially means designing
50%
in TOC Full
Keeps the bottleneck machine running as efficiently as
possible
Allowance for catch-up if & when stoppages occur
Heuristic Critical Product
Machine
Catch up time Dynamic accumulation Flow
How long can a machine stop without disrupting NORMAL
operation of the line
Upstream of CM
Make allowance for upstream machines to stop without
disrupting CM by keeping container population 90-100% full 100% Full
Downstream of CM
Make allowance for downstream machines to stop without
disrupting CM by allowing space on conveyors 50% full
Item Returnable Line (%) Non-Returnable Line Can Line (%)
(%)
Crate / Case Depal 135 135 NA
Bulk Depal 120 120 120
Uncaser 130 120 NA
Crate Washer 130 NA NA
Bottle Washer 120 NA NA
Rinser Gripper / Twist 115 115 NA
Rinser Blocked 110 110 110 Gravity
EBI 110 NA NA
Filler 110 110 110 (New) / 100 (old)
Tunnel Pasteuriser 100 100 100 / 105
Dual Labellers (Single) 120 [2]; 110 [1]; (120) 120 [2]; 110 [1]; (120) NA
Crate Accumulator 130 130 NA
Packer 130 125 125
Shrink NA 120 120
Tray Packer NA 125 125
Palletiser 135 135 135
Stretchwrapper 140 140 140

Calculations
42
Dynamic Accumulation
Calculate conveyor width based on number of slats
Calculate number of bottles that can nest across

Nesting is the affect of the bottles arranging themselves in a set
pattern allows to optimum bottle to bottle contact and flow,
and minimises lock-up
Given Width, Bottle & number of bottles number of

bottles per running meter
Given conveyor speed, length, width & bottles per Product Flow
running meter accumulation time

Chamdor Line 7
40000 bph
Castle Lite 440 ml
68 mm
10 Conveyor slats @ 3.25
Wc = 9 x 90 + (2 x 50)
= 910 mm

() = +1
30
910 68
= +1
68 0.866
= 15.297 = 15
Product Flow
() = 1 30 + D
= 15 1 68 0.866 + 68
= 892.456 + 10
= 902.456
902
902
= 1000
= 1000 68 15
= 220 902

/
=
/
902
40000/60
=
220
= 3/
= 2 = 6.1/ min
1 1
=

= 15 0.166 = 2.5
Conveyor length can be back-calculated too given the

Accumulation time and Accumulation time per metre

Velocity and Speed changes
Typically 7 20 m/min
Bulk speed Sb speed of bulk glass on conveyor
Conveyor speed - Sc = 2 x Sb (max. 21 m/min)
Centre of gravity of bottle determine capability to resist toppling

m Container mass
g 9.8m/s - Gravitational Acceleration
r Radius of container footprint
Stability angle of container
CoF between container & chain

Consider gravity acting on the bottle
Vlimit reduced 19.4 m/min 14.4 m/min

Conveyor Speeds ideal: 14 20 m/min
Infeed & discharge: 80 100 m/min (single file)
Sc > 60 m/min stepped speed changes (min. 2)
Step changes < Vlimit
Guideline
Sc > 40 m/min reduced by 2
Sc < 40 m/min reduce by 3
If Vmax cannot be achieved by Vlimit reductions
Full Bottle / Empty Bottle

Max incline 6 / 4
Decline 4 / 4
Tools
53
Line Simulation
Software capability to simulate the actual operation
of the line
Uses
Develop a new line and test the logic and capability
Problem solve and adjust a current line for optimisation
Can support business case for upgrading
Must have all the inputs to create an accurate logic

system
Machine inherent efficiency
Machine failure characteristics
Conveyors logic

Data set GROUP No. of % of Cumula Cumula
Stops Tota tive tive %
35 22 63 6 49 19 15 l Freque of
Stop ncy Occurre
46 19 16 31 24 29 36
s nce
68 42 57 64 8 23 47 From To
Cumulative stoppage frequency incl. Inc.
21 51 7 40 19 46 16
6 20 12 24 12 24
distribution 32 108 33 55 32 22 36 21 35 14 28 26 52
36 50 12 24 38 76
If software is not available 25 27 37 58 39 10 42 51
66
65
80
7
3
14
6
45
48
90
96
28 72 13 51 45 77 16
81 95 1 2 49 98
Allows us to calculate sufficient accumulation 96 110 1 2 50 100
TOTAL 50
to satisfy 95% of inherent failure
System
Records all stoppage durations
Group all stoppage durations into equal batches
Determine % split of contribution to TOTAL time
Draw graph of cumulative stoppages
@ 95% mark cut the graph to obtain seconds of
accumulation required

1800
1600
1400
1200
High Speed
1000
Med. Speed
800
Low Speed
600
400
200
0

Medium-Below
Leads to constant over-

speeding of machines
Higher wear rates
Average medium line output Higher raw mat & utility

usage
Medium-Above
Machine run at lower

speeds
Less consumption
Raw mats
Utility

Crates & Pallets
58
Number of crates = static accumulation of all conveyors from unpacker to packer + all bottles in
machines on wet end number of crates accumulated between unpacker and packer conveyors)
x breathing factor

M1 1 1 0 1 1 Concepts
P1 0 0 1 1 0 Sensor upstream stops motor
P2 0 1 1 0 0 Sensor downstream starts motor
M2 1 0 0 1 1 Motor operates on/off only
Time delay on sensor

45 000 130%
=
12 55

= 89

= 1.5

=
FLT max travel distance = 125m one-way 250m
250 Basic travel time of FLT with load = 1.14m/s
=
1.14 / sec 60
= 3.7
= 16.2
89
=
16.2
= 5.49 6 ( 3 )
Avg FLT stoppage timer per hour = 10min (restroom, breakdown, etc.)
Palletiser produces 1.5 pallets/min
FLT speed = 1.14 x 60 = 68.4 m/min
Trip rate FLT = 68.4/250 = 0.27 trips per minute

45000 bph @ 12 bottles/crate / 55 crates / pallet
Startup duration = 2hr

1st hr @ 130% [45000/(12 x 55)] x 1.3 = 88.64 pallets
2nd hr @ 100% [45000/(12 x 55)] x 1 = 68.18 pallets
Pallet reject rate = 15%
Empty pallet stack height = 15 pallets high
1 = 89 15%
= 13.3 89 13.3 = 75.7
2 = 68 15%
= 10.2 68 10.2 = 57.8

75.7 + 57.8
=
15
= 8.9 (9)
13.3. + 10.2
=
15
= 1.57 (2)
Total of 11 (9+2) pallet stacks must be available after Depal
Frequency of reject removal stacks? 60
=
0.93
@ 130%: = 89 15%
= 64.3
= 13.3 14
3 :
14
= = 3 64.3
15
= 3.2
= 0.93
@ 100% = 4.1

Control Logic Principles
67
Truth Table (M2) Speeds
M1 1 1 1 1 1 1 CS M1 x 2 Catch up speed
C1 0 0 0 1 1 1 V+ M1 / 2 Build accumulation
C2 0 0 1 1 1 1 V M3 + X% Synch speed + to allow for slight back pressure
C3 0 1 1 1 0 1 V-- M3 Y% Slight speed reduction to create gaps at C1
M3 1 1 1 1 1 0 V- M3 + Z% Pressureless priming
OUTPUT (M2) CS V+ V V-- V- 0 0 Stop
Machine 1 C3
C2
Machine 2
M1 C1 M2 M3

Machine B
Machine B Speed = 100 + %
Backup Stop Control Sensor
Backup Slow Speed Sensor
Direction of flow
High Speed Sensor
High 2 Medium Speed Sensor
Medium Speed Sensor
Medium 2 Slow Speed Sensor
High Prime Sensor
Low Prime Sensor
Machine A Speed = 100%

Machine A

Machine B
Machine B Speed = 100%
Direction of flow
High Speed Sensor
Medium Speed Sensor
High Prime Sensor
Low Prime Sensor

Machine A

Machine B
Direction of flow
High Speed Sensor
Medium Speed Sensor
High Prime Sensor
Low Prime Sensor
Machine A Speed = Stopped

Machine A

Machine B
Machine B Speed = 100 - %
Direction of flow
High Speed Sensor
Medium Speed Sensor
High Prime Sensor
Low Prime Sensor

Machine A

Machine B Speed = Stopped Machine B
Direction of flow
High Speed Sensor
Medium Speed Sensor
High Prime Sensor
Low Prime Sensor

Machine A

Machine B
Direction of flow
High Speed Sensor
Medium Speed Sensor
High Prime Sensor
Low Prime Sensor
Machine A Speed = 100 + %

Machine A

Machine B
Direction of flow
High Speed Sensor
Medium Speed Sensor
High Prime Sensor
Low Prime Sensor

Machine A

Machine B
Direction of flow
High Speed Sensor
Medium Speed Sensor
High Prime Sensor
Low Prime Sensor
Machine A Speed = 100 - %

Machine A

Machine B
Direction of flow
High Speed Sensor
Medium Speed Sensor
High Prime Sensor
Low Prime Sensor
Machine A Speed = 100 - %

Machine A

Considerations
78
Today Tending to High-clean, Ultra-clean & Future expansion / growth
Aseptic
SKUs
Procedure for Equipment & Conveyor design
found Staffing capability
GLT.PK.PR-0935
Things to remember for Conveyors

From BW EBI
From Filler to Labeller
Must contain points for auto / manual CIP
Must consider layout requirements

Adhere to principles of layout for future
packaging lines / halls
Understanding your line
84
Phase 1
Gather historical data
Gather current data
Conveyor speeds, accumulation & control
philosophy
Phase 2
Study of the complete line
DT analysis of filler
Individual machine profile & performance
Waste aspects
Container handling
Equipment QC measurement

Previous 60 shifts worth of data
Quality results from all machines on the line
Clock all machines to ID their actual
efficiency & rating - @ overspeed
Measure performance of filler ONLY
THEN, Measure performance of all
machines over 4 hrs
ID MER from actual profile & inherent
efficiencies
Tools developed to calculate
MTBF
MTTR
MER
And display graphically
Measure all conveyor operation & develop
truth table
6 hr machine study for DT analysis and
inherent efficiency
Filler
Pasteuriser
Glass bottle handling
Quality recording
Crate washer, EBI, BW, Filler, Past
Waste calculations
Raw mats, MEL, Utility consumption
If required Simulation

Zane Hechter
Packaging Trainee - COF
zane.hechter@za.sabmiller.com
m +27 (0)71 866 5324
t +27 (0)11 305 0211

Conveyors and Line Logic - Zane Hechter

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Packaging Trainee

SABMiller 2014 Presentation information in footer

o To move product from one point to another

o To allow for buffering between process areas

SABMiller 2014 Presentation information in footer

SABMiller 2014 Presentation information in footer

Based on return roller spacing

Gap/distance between B 400 450 500 550

Acceptable Cantery sag Y 50 75 100 125

Should be designed to make contact on set points on bottle

Lower Guide Rail After Labeller

SABMiller 2014 Presentation information in footer 8

SABMiller 2014 Presentation information in footer 9

SABMiller 2014 Presentation information in footer 10

More susceptible to brewery

SABMiller 2014 Presentation information in footer 11

Optimal height 1.4m Break in period 0.5-1% stretch

Most Common Uses

SABMiller 2014 Presentation information in footer 15

SABMiller 2014 Presentation information in footer 16

Air-tightness control by air-tight flange connections

Full access to all sections allow for effective cleaning

Dry lube system to optimise CoF

SABMiller 2014 Presentation information in footer 17

Steel, aluminium, PVC, zinc-plated steel

SABMiller 2014 Presentation information in footer 18

Can handle a very wide range of products

SABMiller 2014 Presentation information in footer 19

Two or more chains in parallel

SABMiller 2014 Presentation information in footer 20

Reduce power demand on motors Can cause EBI rejects

Reduce line pressure by allowing for slip Cost

Reduce noise levels If biocidal properties not correct slime production

Assist with stability of moving bottles gentler acceleration

SABMiller 2014 Presentation information in footer 22

CoF: 0.06 0.125 CoF: 0.12 0.18

SABMiller 2014 Presentation information in footer 23

Create loop to equalise pressure over nozzles

Install drip trays

Water pressure 3.5 bar

Chain lube concentration 0.3 2%

CoF 0.13 after 3 minutes

SABMiller 2014 Presentation information in footer 24

SABMiller 2014 Presentation information in footer 25

SABMiller 2014 Presentation information in footer 26

Pressureless combining from mass single feed

Some machines require single file infeed

SABMiller 2014 Presentation information in footer 29

SABMiller 2014 Presentation information in footer 30

Dosing runs no-slip with optimised

Gravity and geared slat chains

All bottles in single file before

Photocells detect gaps on the single

M03 constantly varying to balance

Speed of discharge based on

SABMiller 2014 Presentation information in footer 31

SABMiller 2014 Presentation information in footer 32

SABMiller 2014 Presentation information in footer 33

SABMiller 2014 Presentation information in footer 35

SABMiller 2014 Presentation information in footer 36

MTBF mean time between failures Dynamic accumulation

Micro / macro stops Static accumulation

SABMiller 2014 Presentation information in footer 38

Crate / Case Depal 135 135 NA