In the packaging industry, where every interruption can result in productivity loss, accumulation systems become strategic components to maintain performance and output. One ideal solution is the BAT Buffer by M.H. Material Handling, which we explore below.

The Heart That Keeps Your Line Alive

The BAT Buffer operates using a LIFO (Last In, First Out) logic and is designed to manage micro-stoppages typical in packaging lines. In the event of a downstream stop, the system automatically diverts incoming products to the accumulation buffer, keeping upstream machines running.

The BAT Buffer features a spiral structure that alternates straight and curved sections. This design maximizes available space, offering up to 150 meters of accumulation capacity with a single motor. The straight sections range from 2.5 to 6 meters, while the curves have an average radius of 200 mm, allowing adaptation to complex layouts.

Precision Control, Down to the Millimeter

During loading, products are guided into the buffer with a consistent pitch, regulated via inverter, preventing overlaps or damage—crucial for delicate or pressure-sensitive packaged goods.

Once normal operations resume, the BAT Buffer reverses direction and gradually releases the products back into the production flow. This can be done via an orthogonal transfer unit (to maintain product orientation) or a dynamic combiner for high-speed lines.

The average emptying time, from a full configuration, ranges from 15 to 25 minutes depending on installed capacity and downstream speed.

Recover What You Thought Was Lost

One of the BAT Buffer’s standout features is its ability to recover production lost to micro-stoppages. If downstream machines have an extra 10-20% capacity, the system can completely eliminate these losses by the end of a shift.

Its mechanical structure also enables quick switching between loading and unloading phases without needing full accumulation, helping to regularize the production flow. This operational flexibility makes it ideal for lines subject to frequent format changes or sudden production peaks.

Engineered to Fit, Wherever Needed

The BAT Buffer is ideal in sectors where output sequencing is not critical:

• Bakery and confectionery products
• Coffee and vacuum-packed goods
• Other long shelf-life items

The structure is available in anodized aluminum for standard applications or AISI 304 stainless steel for environments requiring higher hygiene standards, such as cleanrooms. It supports occasional washing without compromising performance.

Its pressure-free design and modular components make it suitable for integration into existing plants, facilitating revamping operations.

See It Live

For those interested in discovering the BAT Buffer’s full potential, M.H. Material Handling will be exhibiting at IPACK-IMA 2025 in Milan from May 27 to 30, Pavilion 7, Booth B21.

For the first time in Italy, the compact infeed/outfeed system of the BAT Buffer—already praised at FachPack 2024—will be presented. Visitors will also get a sneak peek at an exclusive feature designed for those who recognize technical evolution at first glance.

When it comes to optimizing efficiency in modern production layouts, one solution makes a real difference: the spiral conveyor.
Compact, versatile, and tireless, the spiral is one of the most effective technologies for utilizing vertical space, streamlining flows, and ensuring operational continuity—even in the most complex plants.

But be careful: not all spirals are the same.

To get the most out of your line, choosing the right spiral is essential—and the details make all the difference.

Which spiral is better? It depends on your needs:

• Tabletop chain spiral → ideal for high-speed, compact layouts with packaged products
• Modular chain spiral → perfect in environments requiring sanitization, frequent washdowns, and the handling of unpackaged products

Transported materials, hygiene requirements, cleaning frequency, available space: every plant is unique.

In this post, we guide you step-by-step through the key technical and practical differences, share a real case study, and help you identify the perfect spiral for your packaging line.

Tabletop Chain Spirals: Maximum Efficiency, Minimal Footprint

Tabletop chain spirals are designed for durability and consistent performance, even at high speeds. Equipped with roller bearings that increase load capacity and strength, they’re ideal for:

• Packaged products with minimal sanitation requirements
• High-speed applications requiring continuous flow
• Compact layouts with space constraints
• Product flow from primary packaging to palletizing

If you’re looking for maximum efficiency in a compact layout, this is the spiral for you.

Our collaboration with Ambaflex has proven the reliability of this technology—delivering top performance and optimized design even in space-critical settings.

However, be aware: this is not the right choice for environments that demand high hygiene standards.

Modular Chain Spirals: Sanitization and Flexibility

In more sensitive environments, where cleaning is a priority, modular chain spirals provide a key advantage.

Made from food-grade certified materials, they ensure:

• Enhanced hygiene and cleanability
• Design that minimizes product and water retention
• Compatibility with unpackaged products
• Seamless integration with ovens, freezers, or coolers

This is the ideal choice for clean rooms, post-process zones, or areas with frequent washdowns.

The Most Advanced Solutions?

Our partner Intralox offers multiple advanced options, including:

• OverDrive – Ideal for mixed environments with semi-packaged products and freezer exits
• SideDrive – Offers greater layout flexibility and high washdown capability
• DirectDrive – Optimized for extreme environments, including sub-zero temperatures

Thanks to our partnership with Intralox, we’re licensed to build OverDrive and SideDrive spiral systems for our applications.

The Right Choice Comes from Real Needs

There’s no “one-size-fits-all” spiral—only the one that best fits your plant.

If you handle packaged products and need speed, compactness, and reliability, the Ambaflex tabletop spiral is a great solution.

If your environment requires frequent washdowns or delicate product handling, the Intralox modular chain spirals offer top-notch safety and hygiene performance.

A Real Case: When Hygiene Is the Priority

Let’s get practical.

One of our clients needed to install a spiral conveyor in a clean room with frequent washdowns—even though the food products never made direct contact with the conveyor.
Here, the priority was minimizing water stagnation and ensuring rapid, effective cleaning.

The solution?

A modular chain spiral, built for hygienic environments and low maintenance. A system that delivered safety, reliability, and long-term performance.

Need Help Choosing the Right Spiral for Your Line?

Let us help.

With our MH Scan Solution, we offer a free technical check-up of your production line. We’ll analyze your plant layout, identify critical needs, and propose the most effective, safe, and goal-aligned spiral system.

Request your free check-up today and discover how to truly optimize your space and product flow.

Finding the right time to perform maintenance on your conveyor belts can make all the difference for your business. With the right method and proper knowledge, maintenance can become a real advantage—without unnecessary downtime.

If you want to know whether it’s time to replace your conveyor belt and learn more about our scheduled maintenance programs, don’t hesitate to contact us.

Thanks to the MH Scan Solution service, we analyze your packaging line to identify areas for improvement and offer you the most effective solutions to boost productivity and make your line truly competitive.

Packaging line automation represents a major opportunity to boost production efficiency, especially in emerging markets. However, to achieve real benefits, every phase of the process must be carefully planned.

In many facilities, automation stops at primary packaging, with downstream processes still relying heavily on manual labor. While this might seem like the easiest and quickest option, it limits productivity and scalability.

The implementation of new automated systems should not be improvised but must respond to a clear goal: reducing format variability and improving production flow. The temptation to rapidly replace manual operations with advanced machinery must be balanced with a critical consideration: the flexibility of human operators is difficult to replicate without substantial investment.

Planning Automation: Space, Ergonomics, and Logistic Connections

One of the most critical aspects of integrating new machines is managing the available space. It’s not just about the machine’s physical footprint, but also the area needed for operation, maintenance, and safe operator passage. From the start, it is essential to consider ergonomic implications: a line that hinders staff movement or access to equipment not only reduces efficiency but also increases the risk of accidents.

Furthermore, automation cannot be separated from warehouse logistics. Increasing productivity inevitably means more inbound and outbound material flow. Without an automated system for product handling and transport, bottlenecks may arise that cancel out the benefits of automation. Elevators, shuttles, and warehouse robotics are becoming indispensable to ensure operational continuity.

A Step-by-Step Approach: Why Phased Automation Works

Many companies, driven by the need to stay competitive, try to implement automation all at once. While this approach may seem faster and more effective, it carries several critical issues. A radical overhaul may cause weeks or months of production stoppage, significantly affecting operational costs and order fulfillment.

Instead, a gradual implementation allows each phase to be validated before moving forward. This approach minimizes errors, helps operators gradually adapt to new technologies, and ensures that each integration is optimized for the existing workflow.

The goal of well-structured automation is not only to boost productivity but also to ensure a smooth transition without compromising product quality or line organization.

M.H. Material Handling: Your Partner for Smart Automation

Transitioning to automation requires experience, expertise, and strategic vision. M.H. Material Handling supports companies in designing and implementing customized automation solutions that balance innovation, efficiency, and operational sustainability.

Through our MH Solution Scan service, we provide a detailed analysis of your packaging line to identify improvement areas and recommend the best solutions. If you’re considering automation to increase productivity and streamline flow management, contact us for a personalized consultation and discover how we can help you transform your production line into a high-efficiency, competitive system.