A video shows (at the beginning) the random, uneven throughput which lacked the customers requirement of 12" minimum spacing between loaves. To resolve the issue, our experienced electrical team incorporated pulse and photo-eye sensors; a CompactLogix processor, PowerFlex 525 drives; servo motor controllers and VFD's, to develop a new merge concept solution that alleviated the big gaps between product while allowing for more consistent spacing.
A virtual axis measures “pocket length” on the merging conveyor and a pulse is generated in specified inch increments of travel. A product is then released to the pulse on a FIFO (first in, first out) basis. Whichever one arrives first is released first, but to the pulse.
As the video shows, this technology allows us to have the same merge throughput running at 70% of the conveyor speed required previously. To invert that, we could merge 30% more product at the previous conveyor speed.
Key sanitary features were stainless steel welded frame design, continuous welds (ground and polished); stainless steel drives and drive mounts; stainless steel idle ends; washdown duty motors, and reducers.