Big containers, big output done Nature's Way (sidebar)

The plant’s current production setup will fill either 1- or 2.5-gal containers. The 2.5-gal filling line is separate and runs parallel to the 1-gal line until casing. There the two lines combine just ahead of the servo-controlled Douglas laner upstream of the case packer. The 2.5-gal containers are manually unloaded for automated debagging on equipment from Custom Metal, similar to that on the 1-gal line. After they are discharged in rows onto the main conveyor, the containers are labeled by a Label-Aire unit. The containers are conveyed parallel to the 1-gal conveyor into the filling room on 400’ of overhead conveyor. Inside the filling room, a 6-station indexing filler supplied by Reid Plastics transfers the filled containers at a rate of 30 containers/min to an integrated closure applicator also from Reid. In continuous motion, the dispensers are captured one-at-a-time by the passing containers and are then pressed on. The containers are packed onto the erected blanks at a rate of 15 2-count cases/min and continue on for palletizing and stretch wrapping.