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Mass flow = efficiency squared

Unilever cleans up on faster changeovers and washout for monobloc mass-flow fillers on tool-less changeover lines. Network yields big savings.

The monobloc filler (left) permits 15-min washouts that are crucial for fast changeover of the nine detergent formulations run.
The monobloc filler (left) permits 15-min washouts that are crucial for fast changeover of the nine detergent formulations run.

Two lines at Unilever U.S.’s Baltimore, MD, plant prove that mass-flow filling equals efficiency squared. Also, communications on the lines equate to a highly positive subtraction: Off-board controls and networks saved hundreds of thousands of dollars (see sidebar).

In December 2000, the plant inaugurated the first of the new lines for its Liquids Operations. The goal was to achieve a 25% increase in daily output to satisfy sales growth. The products run on the lines include laundry detergent brands Surf, Wisk, and All in sizes of 100, 200, and 300 oz.

Unilever found that the first line can produce 25% more cases of product per eight-hour shift. That’s a record-breaking pace at the plant.

One good line deserved another, and so 18 months later, this summer Unilever started up a virtual duplicate of that line. For both lines, the major equipment was supplied through divisions of Barry-Wehmiller (St. Louis, MO). The centerpiece of the line is a monoblock filler/capper from Pneumatic Scale (Cuyahoga Falls, OH), the first mass-flow filler from the company. Before and after the filler, respectively, are a rotary uncaser and rotary case packer, both from Zepf (Clearwater, FL).

The first line has been full out on 300-oz F-style high-density polyethylene bottles since the start up, according to Unilever’s Cal Soper, who oversees plant TPM (Total Productive Manufacturing) operations that include these projects. Other members of the project team include plant engineering manager Mike Green, senior controls engineer Ted Angil, and senior packaging systems engineer Mike Massimini, among others.

The line’s layout allows for operation by one operator versus the two operators that are typically required, according to Soper. Notably, changeover on the line is entirely tool-less. “It’s all quick-change, quick-maintenance,” says Soper. “Before, a changeover required four hours and four mechanics. Now we can do it with one operator and one other person in one to two hours without tools.” Change parts allow the new line to be changed over between all three sizes.

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