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Rayovac charges up battery lines

Two new production lines package AA and AAA batteries, respectively, into peggable, reclosable RPET clamshells. Integrated setups include self-designed battery handling systems.

Integrated section comprises 8-up clamshell denesting onto a custom conveyor that moves left to right (above). Midway of the mac
Integrated section comprises 8-up clamshell denesting onto a custom conveyor that moves left to right (above). Midway of the mac

Like negative and positive poles, the building and machinery at Rayovac’s packaging operations in Madison, WI, are a study in opposites. Although the historic facility dates back to 1916, it houses two of the latest battery packaging line layouts started up in the latter half of 2000.

The two lines, one for AA and a second for AAA batteries, were designed with flexible dedication in mind. While each line is dedicated to a single battery size, each line can pack three configurations: eight-, 10- and 12-count packs. The packages use clear, reclosable recycled polyethylene terephthalate (RPET) clamshells in combination with a hole-punched graphics header card (see Oct. ’00, p. 38) that makes them peggable for retail display (see graphic below).

Due to the AA batteries’ greater sales, its line received priority, starting up last August. The AAA line was running two months later. Packaging World’s visit concentrated on the AA line for which Algus Packaging (Dekalb, IL) supplies integrated machinery comprising clamshell denester, clamshell conveyor, pick-and-place units for battery and cardstock placement, and clamshell closing equipment.

Rayovac declines to identify rates other than to acknowledge it currently runs at more than 50 packs/min. However, packaging output for the AA line was to double when Rayovac added a second battery feeding system from a nearby line in early ’01. The line configuration was designed for that change from the outset.

The batteries are introduced into the straight-line indexing flow of the clamshell conveyor by a Rayovac-designed battery orienting and infeed system. The incoming battery flow comes in at a right angle about midway of the main machine.

Well-served by servos

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