Alert: Packaging World now enhanced for the iPad and iPhone. Watch a quick video preview
 
Download this free, 140-page Flexible Packaging Playbook jam-packed with strategies for success, best practices, and pitfalls to avoid.  Learn more »
Glenroy invites you to download this playbook.
Article |

Filler meets tough standards at Stonyfield (sidebar)

Cartoner delivers downstream
Print Reprint
FILED IN:  Machinery  > Inspection  > Checkweighers
     

At Stonyfield Farm’s Londonderry NH facility eight packs of Yo Squeeze are loaded into a printed folding carton by a new IH-2 cartoner from Elliott Manufacturing (Fresno CA). The IH-2 cartoner was added last year to accommodate the stick packs. Cartoning is currently the only automated function downstream of the vertical form/fill/seal equipment.

Four packs discharge from one vf/f/s machine directly into a pocket of a new straight-line pocketed conveyor from Uni-Pak (Bradenton FL). The conveyor advances before four tubes from the second vf/f/s are discharged into the same pocket. “The filler conveyor and cartoner are precisely controlled” says John Daigle Stonyfield’s vice president of operations. “So when the filler makes four tubes it sends an impulse to the conveyor to move which sends a pulse to the cartoner. They’re all connected electronically so the timing works.”

The conveyor carries eight tubes per pocket from the vf/f/s machines to the cartoner. During that 70’ span the tubes are conveyed through an enclosed refrigerated tunnel that lowers product temperature down from about 90°F to 40°F. “This allows the liquid to cool into the finished creamy consistency of yogurt” explains Daigle.

ADVERTISEMENT

At the end of the servo-driven conveyor the eight tubes drop 2’ along vertical guides or chutes onto the pocketed conveyor of the IH-2. A vacuum pick head uses suction cups to pick a preglued carton blank from a magazine and open it. The 20-pt clay-coated newsback stock is offset-printed in four colors by Old Dominion (Madison Heights VA). A product insertion ram gently pushes the sticks by their ends into the open carton (as shown). Hot melt adhesive is applied to end flaps and the ends are compressed before the carton is discharged.

Cartons receive an expiration date/time code on the corner of the back panel from an ink-jet coder supplied by Markem (Keene NH). Next cartons are conveyed through an older metal detector and checkweigher. “If there’s a short weight the carton is kicked off onto one conveyor and if there’s metal detected the carton is discharged onto another conveyor” Daigle explains.

Cartons are conveyed into a cooler where they’re manually case-packed. This is a step that Daigle admits “creates some overall line downtime but we envision automating this process in the future.” Cases are then taped shut on both top and bottom and stacked on pallets. Cases from pallets holding a specific product variety are selected manually and then placed on pallets to meet orders. These pallets are stretch-wrapped manually for distribution.

See the main story that goes with this sidebar: Filler meets tough standards at Stonyfield

Comments(0)

Add new comment

E-BOOK SPECIAL REPORT
42 Best Package Designs
Sign up to receive timely updates from our editors and download this e-book consisting of our editors' picks of most notable package designs. Updated for 2014!
x

 

Newsletters
Don’t miss intelligence crucial to your job and business!
Click on any newsletter to view a sample. Enter your email address below to sign up!
GENERAL INTEREST

New Issue Alert

Packaging World Magazine

eClip

Breaking packaging news

Packaging Insights

Pertinent packaging issues

On the Edge Blog

Workforce Development

PACKAGE DESIGN/
DEVELOPMENT

Greener Package

Sustainable packaging

Shelf Impact

Package design strategies

Each newsletter ranges in frequency from once per month to a few times per month at most.