M.H. – Material Handling

Luca Fontana

If you are looking for a multipurpose buffer system that can be used in different situations, Heliflex is definitely the right solution for you.

Today I decided to focus on its most classical use, i.e. as a ‘simple’ buffering system, from how Heliflex works to the products for which it is most commonly used.

Thanks to both its cylinders rotating in sync, Heliflex is a very cost-effective system: in fact, it enables the buffer of a higher number of items within a smaller space, thanks to its single motor.

If you would like more information on this multipurpose buffer system and would like to find out if it is right for you, do not hesitate to contact us and ask for our MH Scan Solution, an in-depth diagnosis to analyse and optimise your packaging line.

In the world of chocolate production, efficiency and process quality are essential to meet the expectations of an increasingly demanding market. This need has become even more pressing due to the significant rise in cocoa prices in recent years, pushing companies to optimize every stage of production to remain competitive and profitable.

Among the systems that ensure smooth operations, counterplate transport lines play a crucial role. These systems, designed to support product handling across various production phases, are a prime example of how industrial engineering can enhance performance and reliability in manufacturing processes.

This method is particularly suitable for “hollow products” such as chocolate eggs, bunnies, and other molded figures, as well as pralines—especially irregularly shaped or spherical ones. Given their shape, these products can roll erratically on traditional conveyor belts, making counterplates the ideal solution to ensure proper positioning and stability throughout all production phases.

From Molding to Packaging: How Chocolate Delights Are Made

The chocolate production process is divided into several interconnected stages, all optimized by counterplate transport lines.

1. Molding and Stabilization

The process begins with molding, where raw material is poured into molds to achieve the desired shape. Once solidified, the product is transferred onto counter-molds—mirror structures that ensure product stability and integrity. These counter-molds, known as counterplates, are essential for securing and organizing products during subsequent processing phases, contributing to a smooth and efficient production flow.

2. Feeding the Packaging Machines

At this stage, the counterplates, with products securely nestled in their cavities, are transported to the packaging machines. Here, automated systems like Cartesian or anthropomorphic robots pick up the chocolate pieces for primary packaging. This phase does more than protect the product: the packaging is also designed to enhance the chocolate’s visual appeal, making it ready for distribution and sale. Counterplate transport lines play a vital role in managing flows toward multiple packaging machines, preventing bottlenecks with accumulation systems that reduce waste and ensure operational continuity even during machine downtime.

3. Recycling Counterplates

Once the product transfer is complete, the empty counterplates are reintegrated into the production cycle. Tipping and shaking systems ensure no residues remain, while the return process often takes place on separate levels to optimize space. Before demolding, buffer systems regulate product flow to maximize efficiency.

Advanced Solutions to Optimize Production

In addition to ensuring product transport, counterplate lines incorporate innovative devices that improve efficiency and versatility.

  • Elevators: Lift the plates for precise positioning on the transport line.
  • Buffers: Accumulate products to prevent interruptions in the production flow.
  • Tippers: Flip plates for correct positioning at each phase.
  • Bypass Systems: Temporarily redirect flow to maintain production continuity.
  • Alignment Devices: Ensure every chocolate piece is perfectly oriented for packaging.

Why Are Counterplate Transport Lines Essential?

These systems not only guarantee the final product’s quality but also optimize resource and space management. They help maintain high hygiene standards, minimize waste, and increase overall productivity. Their ability to adapt to various production needs makes them indispensable for chocolate manufacturers.

Optimize Your Production Line: Discover MH Solution Scan

In such a complex production environment, planning and optimizing transport lines are key to maintaining a competitive edge. The MH Solution Scan is the ideal solution: an advanced diagnostic service designed to analyze every aspect of your packaging line in detail. This tool identifies critical areas, proposes customized solutions, and ensures that every production phase is optimized.

Don’t let inefficiencies compromise your production: contact MH Material Handling to learn how we can help you transform your line into a cutting-edge system, ready for the challenges of the future.

In modern packaging lines, palletizer feeding plays a crucial role in ensuring a continuous and smooth production flow. Although the use of low-pressure accumulation conveyors is now well-established, in recent years we have witnessed a real technological evolution that has redefined operational methods in this field.

From Limited Slip Rollers to Modular Chains

In the past, palletizer feeding was mainly managed through friction rollers. Today, the trend has shifted to the use of modular chains with embedded rollers, which, although requiring a higher initial investment, offer numerous advantages.

Modular chains ensure:

  • Simplified maintenance, maintenance operations faster and more efficient. Time reduced by up to 50%.
  • Better product handling, thanks to the denser pitch of the modular chain’s idle rollers compared to friction rollers, allowing for the handling of smaller products and better preservation of their integrity by reducing specific pressure.
  • Long-term efficiency, as the higher initial investment is widely compensated by operational benefits that translate into reduced maintenance costs over the years.

Aerial Lines: An Increasingly Popular Strategy

Another growing trend in feeding lines is the installation of conveyors on high ground, hanging from the ceiling or supported by columns, a solution previously reserved for large productions but now spreading even to small plants.

This is because the advantages of overhead lines include:

  • Space optimization, as they free up the work floor, allowing for better management of areas in the plant.
  • Better ergonomics, as they facilitate operator movement and increase safety within the plant.
  • Integration with automation, as they allow the use of automated transport systems, further optimizing productivity.

This is another interesting point, as the increasing use of AGVs (Automated Guided Vehicles) and AMRs (Autonomous Mobile Robots) for material handling within plants makes it even more advantageous to have free and well-organized spaces.

Feeding Lines with Automatic Format Change: The New Frontier

In recent years, there has also been an increase in demand for feeding lines with automatic format change, a technology that allows switching from one format to another from the control panel. This is pretty much mandatory for aerial lines, where manual changeovers would be extremely time consuming. This solution has become particularly useful for companies that need to manage an increasingly varied range of products or operate in markets where demand changes rapidly.

Automatic format change allows for:

  • Production flexibility: Minimizes downtime during format changes, ensuring continuous production.
  • Reduction of operational costs: Minimizes manual interventions and optimizes the use of human resources.
  • Increased productivity: The ability to quickly change formats allows for maintaining high production volumes, ensuring superior efficiency.

Advanced Solutions from MH Material Handling to Optimize Your Production

At MH Material Handling, we are dedicated to providing tailored solutions to improve the performance of production lines, integrating innovations such as modular chains and overhead lines. Investing in advanced technologies for palletizer feeding is a strategic choice to improve efficiency, reduce maintenance costs, and increase long-term productivity, while maintaining the flexibility needed to respond to the challenges of a constantly changing market.

MH Material Handling is by your side to guide you towards more efficient and versatile production. Contact us to find out how we can optimize your feeding line and ensure its future competitiveness.

Today, sustainability is at the core of many companies’ strategies, especially in the food sector. Consumers are increasingly aware of the environmental impact of the products they buy, prompting manufacturers to look for greener and more innovative solutions.

However, when it comes to food packaging, the issue becomes more complex. It is not enough to choose new environmentally friendly materials; it is crucial to find the right balance between sustainability, safety and food preservation.

In recent years, the use of paper as a packaging material has grown significantly, driven by increased environmental awareness among consumers and increasingly stringent regulations that incentivise the adoption of more sustainable solutions. However, the transition is not without its challenges, especially when comparing the properties of paper with those of plastic.

Paper vs plastic: the technical challenges in food packaging

Despite its widespread use, paper is not the universal solution. This is because in secondary packaging, it performs well, but when it comes to directly protecting food, challenges arise.

First of all, paper does not provide the same level of protection from external agents as plastic does, particularly for foods with a high moisture content or animal fats, forcing many companies to combine paper with plastics or aluminium. This compromise makes the packaging less recyclable and often defeats the sustainability goal that is being sought.

However, there are also paper films with a barrier layer that are recyclable as a monomaterial. These, however, have severe limitations in terms of protection, being suitable only for products with specific characteristics and a very low level of residual moisture.

The problem then is clear: it is not just about sustainability, but about ensuring food safety. Packaging must ensure that the product reaches the end consumer intact and safe. Pushing ‘green’ solutions such as paper in packaging might seem like the right choice, but if this involves adding plastic barriers or aluminium, it risks making the packaging less recyclable and increasing costs without achieving real environmental benefits.

The evolution of packaging machines for sustainable production

With the increasing use of environmentally friendly alternatives such as paper or single-material plastics, but with thicknesses that are becoming increasingly thinner, packaging machines must also evolve to adapt to these new materials, which have very different physical characteristics to plastic.

Traditional packaging lines, designed to work mainly with plastics, need to be rethought to handle sustainable materials efficiently, without compromising packaging speed or accuracy. This requires careful adjustment of the machines to ensure an efficient production process.

At MH Material Handling, we offer targeted solutions to help companies optimise their production lines, integrating processes with sustainable material innovations, without sacrificing efficiency and precision. However, the introduction of environmentally friendly materials also requires specific attention to the handling of products along the packaging line.

For example, in order to guarantee an optimal production flow with reduced packaging, it is essential to limit contact with the side guides as much as possible. In some cases, the use of high-friction chains or belts can be the ideal solution to keep products stable on the conveyors. When direct handling is required, it is preferable to activate and move products from below, thus reducing the risk of jamming and maintaining smooth operation.

But at MH Material Handling we are also firm on one central point: although sustainability is a priority objective, food safety must remain first. There is no point demonising plastic or adopting ‘greenwashing’ solutions that push paper into packaging if this involves the use of plastic barriers or layers of aluminium that reduce the recyclability of packaging. True sustainability implies finding solutions that balance environmental friendliness and safety while ensuring product integrity and production efficiency.

As a concrete example, Saniflex is one of our solutions – developed for the transport of naked products – that meets the most stringent food safety guidelines. Saniflex arose from the need to respond to special situations requiring the reduction of bacterial load in production and packaging lines.

Saniflex is characterised by the following features:

  • Fully washable structure, designed to be free of hard-to-reach areas during cleaning.
  • Easy disassembly without tools, allowing the operator to quickly remove components requiring more thorough sanitisation.
  • Use of materials that are resistant to frequent washing with aggressive chemicals, which is essential to ensure the reduction of the bacterial load.
  • Stainless steel  structure to ensure maximum resistance to intensive washing.
  • Materials certified for direct food contact and cavity-free components to facilitate the sanitisation process.
  •  Covered threads and spacers with gaskets, designed to simplify washing.

Saniflex is designed to make sanitising quick and easy, minimising downtime by allowing components to be disassembled and reassembled without tools. This solution is particularly suitable for keeping the organoleptic characteristics of food intact, effectively meeting today’s food safety and hygiene requirements.

Saniflex is just one of the many solutions that MH Material Handling provides to meet the challenges of the food packaging industry. We also offer elevation systems to optimise space, sorting systems to handle the most complex lines, and accumulation systems designed to maximise production efficiency.

In order to support companies towards a truly sustainable transition, MH Material Handling offers the ‘MH Solution Scan’: a comprehensive analysis of packaging lines, designed to identify areas for improvement and suggest tailor-made solutions. With this tool, companies can increase sustainability without compromising safety or operational efficiency, making their production lines ready to face the challenges of the future.

The introduction of automation in packaging lines represents a challenge but also a great opportunity for food companies, especially in emerging markets.

Yet many lines stop, in terms of automation, at the primary packaging, an indispensable step to get products onto the shelves. However, secondary packaging is an equally strategic step to improve overall efficiency.

Automate to reduce costs? Not so simple

One of the first goals for project managers is automation as a means of reducing the number of operators. But beware: it is important to be aware that automation can impact line flexibility. While manual operations offer inherent flexibility, automating everything can be costly, especially for lines that have to handle a wide variety of formats.

In this context, the goal of automation should be to increase productivity by reducing the variability of formats, while maintaining production flexibility. A winning strategy could be to move products that have less incidence to dedicated or semi-automated lines.

Attention to space: automation requires planning

Space in the factory is another crucial variable. The installation of automated machines requires adequate operating space, not only for the footprint of the machines themselves, but also for maintenance and the continuous flow of materials.

It is therefore essential to carefully plan the layout of the production line, avoiding that new machines obstruct the operational flow or restrict access to working areas.

Warehousing and logistics: connection is key

L’automazione porta con sé un aumento della produzione, che significa una gestione dei materiali più intensa. Collegare efficacemente la linea di produzione al magazzino diventa fondamentale per evitare colli di bottiglia. Per questo motivo, l’uso di pallettizzazione manuale e movimentazione tramite transpallet potrebbe non essere sufficiente. È necessario considerare soluzioni automatizzate per la gestione del magazzino e il trasporto dei prodotti finiti, al fine di garantire un flusso continuo ed efficiente.

Focus on operator safety

The ergonomics of the production line is another aspect that should not be underestimated. When introducing new machines and connecting conveyors, there is a risk of closing vital passages for operators or creating difficulties in the replenishment of packaging materials. Here again, careful planning of the layout is crucial, to ensure that workers can operate safely, as well as guaranteeing an optimal, smooth workflow.

Gradual automation: a strategic choice

It is clear that secondary packaging automation is a strategic investment for food companies. The benefits in terms of efficiency and safety are tangible, but careful planning is essential to ensure that the transition to automation goes smoothly.

Automating a production line in one go can put pressure on the entire plant, with the risk of production being halted for weeks or months. A more prudent strategy is to implement automation in successive steps. This approach allows each step to be tested and validated, gradually training operators and reducing the risks of production downtime.

At M.H. Material Handling, we support our customers at every stage of the automation journey, from design to implementation, ensuring that every investment brings tangible and lasting benefits. Thanks to our vast experience in the sector, we are able to provide customised solutions that meet the specific needs of each company.

Aware of the many challenges that food companies face, we offer an exclusive tool to optimise the entire process: the ‘MH Solution Scan’. This is an advanced and comprehensive diagnosis, designed to thoroughly analyse your packaging line. This advanced technology allows you to precisely identify areas for improvement, suggesting the most effective solutions to increase efficiency, optimise production flow and reduce operating costs.

With MH Solution Scan, you can quickly identify critical points and take the right countermeasures to transform your production. Our team will accompany you all the way, offering you the experience and technology you need to enhance your operations and achieve concrete results. Find out how MH Solution Scan can make a difference in your production line and lead your company towards a future of greater efficiency and competitiveness.

Do you have to minimise the bacterial load that can form on conveyor belts?

Take care to install conveyors with two primary specifications!

When a client describes this kind of situation to us, we pay particular attention to the materials and mechanical components of the product we offer: that is why many of our conveyor belts can also be supplied in stainless steel.

If you want to find out more about this kind of products, get in touch with us!

In recent years, sustainability has become a central theme, not only in mass communication but also in industry. However, when people talk about sustainability, often they only think about the environmental aspect, neglecting other equally important factors, such as economic sustainability.

The packaging sector is also following this trend, increasingly resorting to packaging that uses less plastic or innovative, compostable materials. In parallel, another aspect is becoming increasingly important: production efficiency and waste reduction.

In fact, making production more efficient also means making it more sustainable.

Packaging lines, especially in the food industry, are complex systems consisting of numerous machines working in series or in parallel. Although each individual machine can be highly efficient, the overall efficiency of the line inevitably tends to decrease due to inevitable operational discrepancies or short interruptions.

Conveyors, which act as the circulatory system of these lines, can benefit greatly from the integration of a buffer or accumulation system, which helps to recover lost efficiency.

The role of accumulation systems in the sustainability of lines

Accumulation systems, or buffers, within the line are crucial in keeping the production process smooth. For example, when one machine works intermittently while another requires a constant flow, interruptions in the packaging process can occur. Traditionally, these problems have been solved with simple parking conveyors, but idle stops require more sophisticated solutions to manage production efficiently and without waste.

This is where the BAT Buffer from M.H. Material Handling comes in, an innovative accumulation system that meets these requirements perfectly. At FachPack, we will be presenting an updated version of our BAT Buffer, the result of years of experimentation and valuable feedback from our customers, making it the ideal solution today to ensure smooth, waste-free production.

BAT Buffer: M.H. Material Handling’s solution for efficient and sustainable packaging

The BAT Buffer is a flexible storage system with a configurable structure in anodised aluminium or AISI 304 stainless steel, designed to fit a wide range of products. This spiral device offers up to 150 metres of buffering space using only one motor, a feature that makes it highly efficient in terms of energy and space consumption.

The system is composed of spirals with straight sections varying in length between 2.5 and 6 metres and curves with an average radius of 200 mm, thus minimising the cross section. The technology behind the BAT Buffer allows it to operate with LIFO (Last In, First Out) logic: when downstream machines stop, products are temporarily stored in the buffer. The movement of the chain, controlled by an inverter and a photocell, allows the products to be placed in the buffer without them coming into contact with each other, maintaining zero pressure and preventing damage.

Benefits of the BAT Buffer: efficiency, waste reduction and sustainability

One of the distinguishing features of the BAT Buffer is its ability to manage the flow of products extremely efficiently. When downstream machines come back into operation or in the event of an upstream production stoppage, the buffer can reverse direction and start unloading products. A merging system allows products from the buffer to be mixed with the normal production flow, thus eliminating end-of-shift losses. This process is particularly advantageous for sectors such as bakery products, confectionery, coffee and many others.

Conclusion

In an increasingly sustainability-oriented industrial environment, the BAT Buffer from M.H. Material Handling is an ideal solution for food companies seeking to combine production efficiency and environmental sustainability. With its ability to reduce waste and optimise the production flow, the BAT Buffer not only improves the efficiency of packaging lines, but also contributes to a more sustainable future for the food packaging industry.

M.H. Material Handling will be present at FachPack 2024, Hall 7A, Stand 757, to present the BAT Buffer and other innovative solutions. Don’t miss the opportunity to discover how to improve the sustainability and efficiency of your packaging line!

Sometimes very little is needed to solve even big problems. Such is the case with product handling devices, which, despite their small size, can make all the difference in a packaging line.

It is often thought that large, bulky and expensive machinery is needed to make a packaging line efficient or faster; product handling devices “dispel” this myth and, indeed, confirm the exact opposite.

I start with a premise: these are machines that in their small footprint encapsulate high technological know-how, the result of a detailed analysis of the company’s needs.

I think it is important to make this clarification since, in the packaging industry, one of the challenges is precisely to create value in small spaces through a high-tech approach.

In fact, I always repeat it and I will never tire of repeating it: available space is one of the worst enemies of product packaging; everywhere, and in Italy especially, there is a lack of square meters to dedicate to product packaging operations. Therefore, solving a problem or making a line more efficient by taking up little space is a great added value.

When to resort to a product handling device?

Product handling is one of the most common applications in packaging lines. In fact, the need to rotate products on all possible axes is common to many companies and can be easily met through these devices.

I reiterate easily because, given the size of the devices, they can usually be fitted inside the plant without too much difficulty.

As I said, these are very common devices, capable of solving multiple problems. Let us look at some typical situations.

1) It often happens that the configuration of the product exiting the upstream machine is different from the one required by the downstream machinery; in this case, a product handling device allows the product to be rotated, avoiding inefficiencies or continuous interruptions.

2) Another typical scenario occurs when labeling or marking is required on a different side of the product than the side by which it exits the packaging machine; therefore, product rotation is required prior to this process.

3) Imagine the advantage of being able to “squeeze” flowpacks the packs coming out of a vertical machine so that the pack height is within a uniform tight tolerance, which will allow the downstream case packing machine to produce a smaller box.
A few millimeters gained in all directions that translates into less packaging material, more cases per pallet, and thus, over time, more products per truck. An overall savings that over time will ensure greater sustainability across the board.

As you may have understood from this quick roundup of situations, there are many possibilities and consequently many features of the device to be inserted.

In fact, when I am confronted with a client about these devices I am wont to make it clear how critical device customization is; it is essential to start with a detailed analysis of:

  • specific needs imposed by the line;
  • weight of the packaged product;
  • dimensions of the package;
  • speed of the packaging line.

Last, but obviously the most important, are the axis and direction of rotation of the product. The best way we have found to avoid confusion is to use terminology inherited from boating, so we speak of ROLL to identify the rotation along the axis of motion, Yaw for those along the vertical axis, and finally BECK for the axis transverse to the motion (in English Rolla, Yaw, Pitch).

Only with all this information in hand can you put in a truly efficient product handling device that can make a difference on your packaging line.

At M.H., we have been designing and manufacturing these types of devices for thirty years, supporting companies that need to optimize and make their packaging lines more efficient by offering innovative and technologically advanced solutions.

Aware of the many needs in the industry, we offer companies our MH Solution Scan: an in-depth diagnosis to analyze and optimize your packaging line. This advanced technology examines current processes, identifies areas for improvement and suggests the most suitable solutions.

Aware of the many needs in the industry, we offer companies our MH Solution Scan: an in-depth diagnosis to analyze and optimize your packaging line. This advanced technology examines current processes, identifies areas for improvement and suggests the most appropriate solutions to increase efficiency and reduce costs. Find out how MH Solution Scan can transform your production process and enhance your operations today.

Numerous companies I have worked with were not even aware that with a few small changes and minimal investment they too could optimise their processes in a big way.

Today, I want to share with you a few tricks to optimise efficiency on your packaging lines.

So, the three primary tricks to improve efficiency on your packaging lines are:

  • optimizing space, maybe even developing upwards;
  • analyzing the the line as a whole, underestimating the importance of the systems that connect your machinery;
  • investing in technological innovation.

Discover how the MH Solution Scan can transform your production process and enhance your operations today.

In industrial production, buffering systems play a crucial role in ensuring optimal space management and uninterrupted production.

When handling cylindrical items such as bottles, aerosol cans, and vials, it becomes essential to adopt systems specifically designed to manage disparities in production flow across different processing stages. These systems must balance upstream production with downstream demands and adapt agilely to the varying speeds of packaging machines.

The primary goal of these systems is to ensure that every operational phase integrates seamlessly, even in the presence of fluctuating rhythms. This synchronization is fundamental to maintaining the quality and integrity of items throughout the entire production cycle.

Such consistency and balance in the flow minimize the risk of clogs or unexpected delays, ensuring efficiency and resilience that are essential for the success of any packaging line.

Let’s now take a closer look at the features and advantages of the three buffering systems suitable for cylindrical products: serpentine, recirculating, and reservoir.

  • Serpentine Buffer Systems

Serpentine buffer systems represent the most straightforward and cost-effective solution for managing short stoppages

The adjacent arrangement of conveyor belts, moving in opposite directions, facilitates the transfer of products between different tracks, ensuring sufficient space for accumulation. The speed of the belts is adjusted according to the desired spacing between products, guaranteeing an efficient and safe process.

These systems are particularly useful for “emptying” upstream machines, allowing continuous production without interruptions.

  • Recirculating Tables

For greater accumulation capacity and optimal use of available space, recirculation tables offer an advanced solution.

With a central transit belt flanked by wider belts moving in the opposite direction, these systems efficiently manage product accumulation, effectively handling longer production interruptions.

  • Reservoir Tables

When production needs require product accumulation for extended periods or in the presence of frequent format changes, reservoir tables are the ideal solution.

These systems, with their wide and bidirectional configuration, can accommodate a significant quantity of products, effectively functioning as a buffer.

Solutions for Cylindrical Products with Special Requirements

In addition to standard buffering systems, there are products that, due to their unique shapes, require extra care.

Truncated conical products or those with non-standard circular sections often require ingenious solutions to ensure their integrity during accumulation.

For these special items, we implement proactive measures such as polycarbonate containment covers, which effectively prevent the risk of overlapping or part separation. These precautions are essential for maintaining the excellence and precision of the product up to the final stage of the process.

Successful strategy: Choosing the right buffering system for your production line

Buffering systems for cylindrical products are a key component in optimizing production processes. By implementing specific technologies—such as serpentine systems, recirculatiing tables, and reservoir tables—you can not only maximize production capacity but also preserve the integrity of each individual item.

Attention to the specific needs of various product types ensures tailored solutions that effectively address the challenges of modern industry.

In this scenario, making a well-informed and judicious choice of accumulation systems is crucial not only for solving operational problems but also for optimizing your production line, ensuring a rapid and tangible return on investment.

Refining production requires not only the right tools but also the insights necessary to utilize them effectively. This is where our MH Solution Scan comes into play: an in-depth diagnosis to analyze and optimize your packaging line. This advanced technology examines current processes, identifies areas for improvement, and suggests the most suitable solutions to increase efficiency and reduce costs.

The MH Solution Scan is your ally in production management, designed to provide a tailored analysis of your needs and propose a clear action plan. It answers the question: “How can I improve my packaging line?”

Discover how the MH Solution Scan can transform your production process and enhance your operations today.

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