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Big containers, big output done Nature's Way

Nature’s Way Purewater fills 180 1-gal containers/min and packs them into 3-count cases at a rate of 60 cases/min. New $4 million, 2000’-long line includes a case packer that accepts 2.5-gal containers, too. See in-plant video

Lengthy line starts with robotic depalletizing where the bagged jugs are picked and placed onto an infeed table for automatic de
Lengthy line starts with robotic depalletizing where the bagged jugs are picked and placed onto an infeed table for automatic de

When you think of beverages, filling at 180 containers/min is not considered fast. When the containers are 1 gallon in size, though, that’s pretty fast. High output is just one of the benefits of a $4 million line started up in June at Nature’s Way Purewater, Pittston, PA. The turnkey installation, including engineering, integration, equipment purchases, and networking, was by Crompton Sales (Methuen, MA).

The line fills containers ranging from 2.5-gal down to the 1-gal size that was run during Packaging World’s visit. It operates two shifts five days/week. This line is the first time the three-year-old company has packed gallons, which now represent 90% of the line’s output. The company produces under its own label as well as private label brands.

The high-density polyethylene jugs are received on pallets in nine layers each of a 6 x 8 pattern. Each layer is bagged in low-density polyethylene film. The jugs are supplied by a regional plant of Reid Plastics (Diamond Bar, CA), which also blow molds the 2.5-gal size. The lightweight loads are unloaded manually from a docked trailer truck that backs up to within about 10’ of the line. For the 1-gal size, twin infeed stations, each with its own robot, sit alongside the manual infeed station for the 2.5-gal size (see sidebar).

Twin robots

As needed, a pallet load of jugs is set into position next to either of the two pick-and-place robots from Custom Metal Design (Winter Garden, FL). “Each robot is capable of unloading 120 jugs/min,” says Fred Gubitose, Nature’s Way president and chief executive officer. “Working in parallel, they can easily handle the line’s 180 jugs/min output.”

Each robot picks the top layer of bagged jugs from locations on its opposite sides (see video). When the robot is done unloading one pallet, it automatically rotates 180 degrees to the other position to begin unloading the new pallet. Meanwhile, the operator replenishes the now empty spot with a new load. The robots employ 11 vacuum cups to grip the bagged jugs.

The bagged jugs are placed on a conveyor table before a hot wire-equipped assembly lowers to cut the film. Powered rollers on opposite sides grip the film edges, peeling away the LDPE film, and direct it into a metal bin below the infeed table. The 6 x 8 group of unbagged jugs is conveyed to the next section of the Custom Metal machine where the jugs release via a gate one row at a time.

The jugs transfer at a 90° angle onto the main conveyor that inclines upward to a 11’ height. The overhead conveyor run provides 1귔’ of accumulation across the warehouse. Gubitose is a big fan of lengthy conveyors that can provide an inventory buffer between key operations. This accumulation allows a replacement of the truck trailer without interrupting the flow to the filler, he says. Front to back, the entire line comprises around 2ꯠ’ of conveyor.

Ahead of the filling room, the overhead conveyor declines and the jugs are labeled. That’s done by one of a pair of Label-Aire (Fullerton, CA) Model 2111CDL labelers. Gubitose says that the line keeps running even during label roll changes as the containers automatically feed to the other labeler once the rollstock on one is exhausted.

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