• Conveyor solutions for dairy processing
  • FlexLink components and parts for dairy processing
  • Milk bottling process solutions
  • FlexCAM conveyor solutions for dairy processing
  • FlexCAM conveyor solutions for dairy processing
  • Dairy processing conveyor line
  • Conveyor solutions for dairy processing
  • FlexLink components and parts for dairy processing
  • Milk bottling process solutions
  • FlexCAM conveyor solutions for dairy processing
  • FlexCAM conveyor solutions for dairy processing
  • Dairy processing conveyor line

Dairy Processing Case Study

Problem Presented

Client needed a new conveyor system to improve production efficiency and to meet increasing volume demands. The new conveyor was to handle the unloading of bulk milk bottles through an unscramble to the filling line.

The existing system exhibited issues with transfer of bottles between conveyors and systems requiring constant monitoring and rectification. This resulted in lost production time and increased labour cost as lines had to be manually cleared for the next run. Due to poor product control finished goods were being rejected because of incorrect label location. Maintenance requirements were high and the replacement of custom parts and components was costly. The old system was unable to accommodate new product designs and used up valuable floor space.

Parameters provided:

  • Increase capacity to meet revised production volumes
  • Optimise production efficiency and floor space
  • Reduce maintenance requirements and breakdown impacts
  • Better control of product orientation for labelling
  • Flexibility to handle multiple sized products
  • Improve utilisation of workforce
  • IP66 for wash down areas
  • Minimal impact to existing facility
  • Minimise lost production during installation

Engineered Solution

Utilising our extended range of high quality standard components we designed a space efficient system to fit the existing facility and footprint. By using wedge elevators we moved the production off the ground reducing the use of floor space to 10%. With the help of our inhouse CAD simulation tool we were able to optimise the production flow and assess all safety and hygienic requirements. Working closely with the onsite operations team our engineers perfected the design to ensure production expectations were met and output requirements achieved.

We used a combination of aluminium and stainless steel conveyor systems to offer a cost effective solution to the client. In critical areas where hygienic requirements had to be met we installed our stainless steel systems rated to IP66. While in non-critical sections we used our aluminium conveyor systems to maximise value.

With the help of our automatic guide rail systems we were able to combine three separate lines into a single configurable line capable of handling different pack sizes between nominated minimum and maximum dimensions.  “X-Bend” transfers were used to ensure good control of product during transfer between conveyors and handling equipment.

This was a well thought out and planned project. We anticipated potential issues and responded immediately to find quick solutions. In close co-operation with the customer we delivered the project ahead of schedule and without any interruption to production. The whole system was up and running within 24 hours of final cut in. Apart from solving the original problem, we delivered a fully optimised design offering a long-term quality solution to the client.” Adi Sosiawan, FlexCAM Project Manager

Installation and assembly

In close collaboration with the client we decided on a multi-stage installation schedule. We deployed temporary solutions to ensure continuous operation without the need of any interruption to production. Once no longer required, temporary solutions were re-deployed within the production environment. Parts of the system were pre-assembled and thoroughly tested to ensure trouble free operation prior to installation.

Customer outcome and benefits

  • Capacity increased by 354%
  • Equipment efficiency of 99.99%
  • Zero production loss during installation
  • Change over time reduced by 91%
  • New system released 90% of usable floor space occupied by old system
  • Production rejects (labelling) reduced by 99%
  • Spare parts requirement reduced by 80%
  • Maintenance load reduced by 50%

This project presented unusual challenges due to the complex nature of the proposed conveyor route, length and elevation changes, which FlexCAM successfully resolved without compromising the outcome.” – Ian Morris, Contract Project Manager