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M.H. – Material Handling

Luca Fontana

Dalla 879 alla UltimateSafeChain la stessa affidabilità, ma potenziata

From the 879 to UltimateSafeChain: the same reliability, enhanced

Today’s production lines demand increasingly high standards: higher speeds, lower noise levels, and greater safety.

The historic 879 chain, developed in the late 1980s and established as an industry benchmark, has long proven its strength as a tireless “workhorse” of conveyor lines.

MH Material Handling decided not to settle.

Drawing on nearly forty years of experience and direct, ongoing dialogue with field technicians, USC – UltimateSafeChain was created: an evolution that preserves the robustness of the 879 while integrating with new technologies to meet the real demands of modern industry.

Can something that already works perfectly really be improved?

The strength of the 879 BAT has never been in question: robust, versatile, andlong-lasting, it has earned the trust of operators because it “simply works.”

In particular, tangential drive has proven over time to be the most effective solution for managing LIFO accumulation systems, such as the BAT Buffer, ensuring stability and operational continuity.

However, through extensive field experience and ongoing dialogue with technicians, a key insight emerged: when the foundation is solid, it can be made even safer, quieter, and more efficient.

For this reason, we partnered with Ammeraal Beltech, integrating Safety Finger technology into our new USC chain, a solution already recognized for its strong focus on operator safety.

USC: the reliability you’ve always trusted, even better performance

The new UltimateSafeChain is not a break with the past, but its natural evolution.

It is fully backwards-compatible with existing lines: no system redesign is required—only the chain and sprockets need to be replaced.

The tangible benefits are immediate:

  • Higher operating speeds, increasing productivity without compromising stability.
  • Reduced noise levels, improving operator comfort and supporting compliance with industrial noise regulations.
  • Greater installable length, enabling more flexible and scalable system layouts.
  • Enhanced stability and safety, thanks to the integration of Safety Finger technology, which reduces the risk of accidents and unexpected stoppages.

All of this while preserving what operators already know and value: the reliability of tangential drive, a distinctive feature that continues to deliver top performance in buffering and accumulation systems.

Easy revamping that reduces downtime and hidden costs

One of the most critical aspects of plant modernization is the risk of downtime. Stopping a production line to replace components slows productivity and increases operating costs.

USC was developed with a clear objective: to simplify revamping.

No complex rebuilds, no full replacement projects—just the new chain and the corresponding sprockets are enough to transform an existing system into a more modern, efficient, and safer solution.

This approach fully aligns with the Total Cost of Ownership (TCO) perspective: investing in next-generation components helps reduce hidden costs related to extraordinary maintenance, energy consumption, and unplanned downtime.

Why choose MH Material Handling

At MH Material Handling, every innovation is driven by listening to the real needs of industrial systems.

With USC, we chose to preserve what already works—the robustness and tangential drive of the 879 BAT—and enhance it with new technologies that address today’s requirements: higher speed, greater safety, lower noise, and improved efficiency.

This is not an “off-the-shelf” product, but a solution designed to last over time, reduce risk, and simplify the daily work of those who operate and maintain systems.

That is what sets us apart: transforming conveyors from simple components into true drivers of competitiveness for companies.

If the 879 BAT has been a cornerstone for nearly 40 years, USC – UltimateSafeChain marks the beginning of a new chapter: the same reliability, with higher performance.

Would you like to find out whether USC can make your line more efficient and safer without redesigning the system?

Contact us for a personalized consultation: together, we will assess how a simple upgrade can be turned into an immediate advantage.

Improve the efficiency of your packaging line with our MH Scan Solution
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Cosa succede quando il nastro trasportatore non è quello giusto

What happens when the conveyor isn’t the right one?

At first glance, it may seem like a small detail, just a component connecting one machine to another, nothing more.

In reality, the conveyor is the heart of the line: efficiency, hygiene, safety, and ultimately the quality of the product reaching the consumer all depend on it.

Yet too often, its selection is underestimated, as if one belt were as good as another. But that’s not the case.

Each application is different, every product has its own characteristics, and each plant has its own criticalities.

Treating the conveyor as a “standard” element means opening the door to unexpected downtimes, contamination, waste, safety issues, and hidden costs that grow over time.

A significant share of line stops doesn’t stem from mechanical failures but from synchronization and accumulation problems, a clear sign that conveyors impact production continuity much more than people think.

When the product is “naked” fresh or dry is not enough

Talking about “naked” products means addressing very different worlds. A dry croissant is not the same as a honey-covered bar, just as a filled cake slice cannot be compared to a cracker.

In the fresh sector, hygiene is paramount. Belts must be washable, cavity-free and easy to sanitize. Belts with internal fabric layers are not suitable: if the fabric emerges, it becomes impossible to clean properly.

That’s why monolithic belts are used, more rigid and less flexible, but capable of ensuring the highest hygienic standards.

In the dry sector, the range is broader: brittle products such as biscuits or crackers fit well on modular chain conveyors, which allow easy removal of crumbs.

But when coatings, creams, or jams come into play, PU belts are required, surfaces that can be scraped clean without damaging the belt.

Each product type therefore requires a targeted evaluation.

Packaged products, but where in the line?

Even a packaged product raises specific questions: is it located in a white zone or a grey zone? Does it require washdown capability or not?

Are high speeds, tight transfers, or low noise levels needed?

In general:

  • The tabletop chain conveyor is ideal for heavy loads, high speeds, and complex layouts.
  • The modular chain conveyor offers greater flexibility and smaller wrap diameters, but it’s less robust, has wider curve radii, and requires more maintenance attention.

If we’re in a washdown area, the structure matters too: at least the legs must be in stainless steel, if not the entire frame.

The choice, therefore, concerns not only the belt, but the whole operational context.

The invisible factors that make the difference

Beyond product features and packaging type, there are less visible but decisive variables:

Belt position

On the floor or overhead?

Overhead systems prioritize robustness, since maintenance interventions are more complex.

On-floor conveyors, instead, prioritize operator safety, requiring reduced-pitch chains to minimize risk.

Maintenance

How often will the belt need to be serviced? High frequency calls for easily removable and sanitizable designs.

Format variety

If the line handles multiple product types, flexible and adaptable systems are essential.

Finally, one basic principle must not be forgotten: machines never work in perfect synchronization. That’s why accumulation systems (buffers) are necessary to guarantee continuity and prevent line stops.

At M.H. Material Handling, we know these complexities well. For nearly forty years, we have been designing tailor-made conveyors for every type of line, product, and requirement – from fresh to packaged good.

Our solutions always start from listening: we don’t begin with a standard catalog, but with a real customer problem.

Whether it’s about handling a delicate product, freeing up floor space for operators, or optimizing flows in limited spaces, every project is co-designed together with the customer.

From the washdown SaniFlex line to the BAT system with USC chain, up to the ModulFlex conveyors with modular chains ,each technological choice follows a clear logic: transforming daily challenges into efficient, safe, and long-lasting solutions.

For us, automation doesn’t mean selling a machine, it means designing together the right answer to a real need.

Want to understand which solution best fits your line?

Contact us for a personalized consultation and discover how to make your system smoother, safer, and more efficient.

Improve the efficiency of your packaging line with our MH Scan Solution
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Migliora la produttività sulla tua linea di confezionamento

Improve Productivity on Your Packaging Line

Increasing the performance and efficiency of your production line often requires a significant investment in both money and space.

However, there are aspects of your packaging line that can be optimized to make the most of the available space and boost productivity — all while staying within your planned budget.

Streamlining the product flow through your packaging process allows you to enhance the productivity of your entire production line. With the right solution, you can achieve this while respecting space constraints and maintaining sustainable costs.

If you want to find out which solutions best suit your needs, contact us and request our MH Scan Solution service: we will analyze your packaging line to identify how to refine and optimize your production setup.

Improve the efficiency of your packaging line with our MH Scan Solution
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Hygienic Design da semplice esigenza a requisito strategico per l’industria alimentare

Hygienic Design: From Basic Need to Strategic Asset in the Food Industry

In the food industry, hygiene isn’t just good practice—it’s an essential requirement for ensuring safety, quality, and regulatory compliance.

But is designing machines that are “easy to clean” really enough?

The answer is no.

Preventing contamination and protecting the end consumer requires a much more advanced, structured, and systematic approach.

That’s why today we’re talking about Hygienic Design: a set of construction criteria, design choices, and specific materials developed to eliminate risk areas, simplify sanitation, and guarantee the highest standards in food safety.

Hygienic Design in the Spotlight: Why It’s Transforming Food Production

In recent years, tighter regulations and a growing focus on food safety have brought Hygienic Design to center stage.

Food manufacturers are dealing with increasingly automated processes—and maintaining high hygiene standards throughout the entire line, including the most complex phases like internal transport and handling, is now a top priority.

Key challenges include:

  • Preventing cross-contamination, both microbiological and chemical.
  • Ensuring fast and effective cleaning of every product-contact surface.
  • Reducing water and detergent consumption to meet both sustainability goals and cost control.
  • Complying with EHEDG (European Hygienic Engineering and Design Group) guidelines, now a benchmark across the European industry.

Hygienic Design Is More Than Just Stainless Steel

Many think Hygienic Design simply means using stainless steel—but that’s only part of the story.

A proper approach starts with material selection but extends to surface geometry, accessibility for cleaning, the absence of gaps and stagnation areas, and tool-free disassembly of washable components.

Among the most common materials, AISI 304 stainless steel with bead-blasted or 2B finishes is standard for frames and load-bearing structures.

But plastic materials also play a key role. For instance, M.H.’s Saniflex system uses polypropylene chains with polyketone pins—highly resistant to the chemical agents used during sanitation.

Saniflex: Designing Hygiene with No Compromise

M.H. Material Handling developed the Saniflex system specifically to meet the toughest requirements of the food industry, particularly in dairy production.

In these environments—where processing fresh and packaged cheese demands absolute cleanliness—standard solutions simply aren’t enough.

Saniflex stands out thanks to:

  • Fully open frame design that prevents build-up and supports efficient drainage.
  • Tool-free removable components for fast and easy daily or deep cleaning.
  • Chains resistant to aggressive detergents but fully compliant with food-grade regulations.
  • Reduction in water and detergent use compared to traditional systems.

The result?

A solution that enhances productivity, guarantees hygienic safety, and supports environmental sustainability targets.

Invisible Contamination: The “Forever Chemicals” Risk

Hygienic Design isn’t just about bacteria and mold.

Today, manufacturers must also consider chemical contamination from persistent substances like PFAS (per- and polyfluoroalkyl substances), often called “forever chemicals.” These may come from the environment, industrial coatings, or even the detergents used on production lines.

Designing equipment that’s easy to clean also means reducing surface exposure to these chemicals.

With Saniflex, manufacturers can:

  • Reduce washing cycles.
  • Use gentler, less aggressive detergents.
  • Minimize the risk of transferring harmful substances onto the product.

When Hygienic Design Becomes a Competitive Advantage

Hygienic Design is a strategic investment that brings measurable benefits:

  • shorter downtimes,
  • longer equipment lifespan,
  • lower cleaning costs,
  • stronger food safety,
  • regulatory compliance.

At M.H. Material Handling, these principles are a cornerstone of our engineering.

With solutions like Saniflex, we combine technological innovation, operational efficiency, and full adherence to the strictest international guidelines.

Wondering if your production line meets today’s hygiene standards?

Book a free consultation with our experts via our MH Scan Solution service: we’ll assess your system’s critical points and show you how to optimize safety, efficiency, and sustainability.

Improve the efficiency of your packaging line with our MH Scan Solution
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Perché la ricerca di sostenibilità nel packaging alimentare sta cambiando il nostro modo di lavorare MH

Sustainability in food packaging: how to keep up?

Switching to sustainable packaging is never easy: it requires time, investment, and careful planning.

One aspect that is often underestimated is the adaptation of conveying systems: without modern solutions, you risk ending up with innovative packaging but a slower and less efficient production process.

At MH, we are constantly committed to supporting you in making your packaging more sustainable. In particular, for the conveying part we offer solutions such as the Magic Sorter or the Intralox END system, both ideal for handling the new types of sustainable packaging.

In addition, with our MH Scan Solution – an in-depth analysis service of your packaging line – we help you optimize the production layout with a view to sustainable packaging.

Contact us to discover how to get your line ready for change.

Improve the efficiency of your packaging line with our MH Scan Solution
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Quando la produttività non può fermarsi l’efficienza del Bat Buffer

When Productivity Can’t Stop: Discover the Efficiency of the BAT Buffer

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.

Improve the efficiency of your packaging line with our MH Scan Solution
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Le nuove sfide del confezionamento tra automazione e sostenibilità

The new Challenges of Packaging between Automation and Sustainability

In the packaging industry, sustainability is no longer an option, but achieving it inevitably involves additional costs.

Automation can provide a concrete solution: by improving the efficiency of production lines, it helps offset the costs required for sustainability, becoming a strategically.

This, of course, requires taking into account three key variables that determine the success of a project.

Integrating automation systems is not always straightforward: structural constraints and limited space often come into play, requiring creative and innovative solutions.

True success comes from finding the right balance between investment, productivity, and space optimization.

This is why at MH we support our clients with MH Scan Solution: our design approach that starts from the very beginning, considers all variables at play, and guides automation toward the best possible outcome.

Improve the efficiency of your packaging line with our MH Scan Solution
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Catena modulare o a tappeto La guida pratica per scegliere la spirale giusta

Modular Chain or Tabletop? A Practical Guide to Choosing the Right Spiral

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.

spirale Ambaflex con catena tabletop La guida pratica per scegliere la spirale giusta
Tabletop Chain Spiral Ambaflex

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.

spirale Intralox con catena modulare La guida pratica per scegliere la spirale giusta
Modular Chain Spirals Intralox

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.

Improve the efficiency of your packaging line with our MH Scan Solution
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Pezzi di ricambio e manutenzione dei nastri trasportatori

Spare parts and conveyor belt maintenance: what you need to know

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.

Improve the efficiency of your packaging line with our MH Scan Solution
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Strategie vincenti per l’automazione delle linee spazio logistica e scalabilità

Winning Strategies for Line Automation: Space, Logistics, and Scalability

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.

Improve the efficiency of your packaging line with our MH Scan Solution
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linea di confezionamento rallentata

What worked 10 years ago could be slowing down your packaging line today

A high-quality packaging line can deliver reliable performance for decades, especially when supported by careful engineering and proper maintenance.

The service life of a system represents significant value, but being fully operational does not always mean it can meet today’s production, technological and regulatory requirements.

New packaging materials, sustainability goals, and increasingly demanding industry standards require systems capable of evolving – a particularly important consideration in the food industry, where hygiene, ease of cleaning, and safety are fundamental requirements.

Do you want to learn how to adapt your system to new regulations and changing production requirments?

Contact us for a technical consultation.

Improve the efficiency of your packaging line with our MH Scan Solution
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Unificatori nelle linee di confezionamentoquando servono e quale scegliere

Lane mergers in packaging lines: when they are needed and which one to choose

Converging multiple product lanes into a smaller number of lanes may seem like a simple operation. In reality, the way products are collected, timed and delivered to the downstream machine can have a significant impact on the consistency of the entire process.

This is why designing a lane merger is not simply a matter of considering line speed. First of all, it is necessary to understand how the product behaves: its shape, stability, fragility, ability to run in contact with other products, and the pitch required by the downstream machine are all factors that help define the right solution.

Based on these parameters, M.H. Material Handling designs the merging configuration best suited to the characteristics of the line and the product.

The first criterion is the product: can it withstand accumulation?

Even before speed is considered, the assessment starts with the product and its ability to withstand accumulation.

A product that can tolerate accumulation can withstand the pressure generated by products touching and pushing against one another. Boxes, trays and products stacked in tightly packed formats fall into this category.

A fragile product, or one prone to overlapping, cannot withstand this type of stress, and a pressure-based system could compromise its integrity.

This is why resistance to accumulation is the first factor to be assessed, as it determines whether a pneumatic or dynamic lane merger is required even before line throughput is considered.

There is, however, one useful exception to bear in mind.

Even with a product that can withstand accumulation, the presence of many formats with significantly different widths often makes a dynamic solution preferable. This avoids format changeovers using adjustable or automatically controlled guides and, because the products do not come into contact with one another, eliminates the risk of misalignment.

Pneumatic, DU Series or HP Series: the right technology for each product

A pneumatic lane merger is the simplest and most cost-effective solution, but it is suitable only for products that can tolerate accumulation.

It operates using gates on the infeed lanes, which release the product rows in sequence, and requires two conditions: the products must be able to withstand pressure during accumulation, and the downstream machine must be capable of receiving products in a continuous train without being adversely affected.

The second requirement has a specific technical reason. At the outlet, the products are close together or touching. When this train reaches the downstream machine, the instantaneous speed seen by the machine is therefore twice the average speed. Either the downstream equipment must be able to handle this, or the flow must be normalised using a deceleration conveyor followed by an acceleration conveyor, at the cost of a larger footprint, two additional motors and more complex control logic.

The pneumatic solution is also well suited to a particular application: where the carton itself is the primary package, as is common in the pasta industry, in the section between secondary packaging and the case packer, where the product can be accumulated.

When, on the other hand, the product is delicate or must be handled without contact, dynamic lane mergers are used. M.H. offers two series.

The DU Series merges products by reducing the number of lanes through anti-overlap timing belts operating at controlled differential speeds, one for each infeed lane. Products are handled individually and without contact, making the system suitable for fragile products or products prone to overlapping, at speeds of up to approximately 240 pieces per minute.

The HP Series is the evolution of the DU Series, developed specifically for high-speed flow-wrapping lines and for connections between primary and secondary packaging. In this case, pressure is completely eliminated because the products must never come into contact. Each item is individually timed by means of a multi-belt system with independent brushless drives for every infeed lane, combined with blower-generated vacuum for higher acceleration rates, reaching up to 600 pieces per minute at the outlet. In flow-wrapping applications, precise product timing is essentially mandatory, as it is the only way to prevent products from overlapping.

Outlet pitch: a detail that should not be underestimated

As speed increases, it becomes essential to achieve the most consistent possible product pitch at the outlet of the lane merger, because this determines how the downstream machine receives each item.

A product flow delivered in trains can push the downstream machine beyond its production limits because of the instantaneous speed peaks described above. Individual product timing, on the other hand, controls the distance between packs and transfers them without contact, reducing the risk of jams and overlaps.

The choice always starts with the product

In every case, the starting point is always the product. The first step is to determine whether it can withstand accumulation, then assess its fragility and shape, the required production rate and the number of lanes to be merged, and finally the type of downstream machine, particularly whether it is a flow wrapper positioned between primary and secondary packaging.

The right technology emerges from these answers: a pneumatic lane merger for products that can withstand pressure, the DU Series for products requiring contact-free handling, and the HP Series for high-speed flow-wrapping applications.

At M.H. Material Handling, we manufacture material-handling systems and efficiency solutions for packaging lines in the food industry and related sectors. Over more than forty years of field experience, from food & beverage to pharmaceuticals and packaging, we have developed the expertise required to identify where lane merging can make a real difference and where it is unnecessary. On this basis, we design customised pneumatic and dynamic lane mergers from the DU and HP Series, starting with an analysis of the production line.

If you are planning a new line or a revamping project and lane merging is still an open issue, we can assess it together to identify the most suitable configuration.

Improve the efficiency of your packaging line with our MH Scan Solution
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BAT BUFFER

Accumulation systems: the mistake is thinking about them later

Is your packaging line inefficient? Just add a buffer and the problem is solved.

Or at least, that’s what many people think.

Adding a buffer to an existing line can turn into an expensive and unnecessary investment. Before proceeding with the installation, carefully assess all the preliminary factors: an in-depth analysis can help you avoid ending up with the same problems you started with.

To identify the most suitable solution for your packaging line, contact us: we’ll analyse your specific case and help you define the most effective solution.

Improve the efficiency of your packaging line with our MH Scan Solution

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Convy VP1

Conveyor: much more than just a connection between two machines

What happens when the connection between the machines in a packaging line is not designed correctly?

The risk is that slowdowns, accumulations, micro-stoppages and disruptions in the flow may occur, affecting the efficiency of the line and, over time, the overall performance of the plant.

This is the idea behind the new video series from ConveyorU, the M.H. Material Handling Academy dedicated to intelligent product handling in packaging lines.

Guiding you through this journey are Convy, the Academy’s mascot, who asks the questions of those who work in production plants every day, and Luca Fontana, CEO of M.H. Material Handling, who answers based on forty years of experience in line design.

In this first episode, they address an apparently simple question: why are conveyors so important?

As the video shows, the value of a conveyor depends on how it is integrated into the line, the required speed, the operating conditions and the specific production requirements.

The required characteristics also vary significantly depending on the industry: a line dedicated to food or pharmaceutical packaging has different priorities compared to an application in logistics, mechanical engineering or the automotive industry.

This is just one of the topics covered by ConveyorU, a journey dedicated to the different aspects of product handling and packaging line efficiency.

Do you want to improve the efficiency of your line?

Every line has different conditions, products and critical issues. To identify areas for improvement, it is therefore necessary to analyse the process as a whole, looking at how the machines interact and how the product is handled.

The M.H. Material Handling team can help you assess your line, identify any critical points and develop a solution based on the actual needs of your plant.

Contact us to discuss your application and discover how to make your product handling more efficient, continuous and easier to manage.

Improve the efficiency of your packaging line with our MH Scan Solution

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bat buffer imballaggio (1)

Less Packaging, More Line Problems. The hidden cost of sustainability on your machinery

It happens for different reasons. Sometimes it is a decision made by the purchasing department aimed at reducing costs. Sometimes the end customer requests less plastic. Sometimes it is compliance with new European packaging regulations, such as the PPWR Regulation. Sometimes it is all of these things combined.

Whatever the reason, when the primary film gets thinner, the package becomes lighter and more deformable.

On the conveyor, however, this means less stability.

On the conveyor, just a few microns change everything

A 28-micron film creates a very different pack from a 40-micron one. Lighter and more flexible, it is more affected by any type of contact – whether with product guides or with other packs in accumulation zones. The risk of deformation or overlapping inevitably increases.

Downstream, this results in micro-stops and scrap, and often in complaints from customers receiving damaged products.

The packaging machine continues to run as usual, but the entire section between production and packaging is no longer suitable for the new format. As a result, speeds, chain type, side guides, and contact surfaces all need to be reconsidered, because the entire conveying section must be recalibrated according to the new mechanical properties of the pack.

The buffer that worked yesterday may no longer be suitable today

An accumulation system is designed based on the real parameters of the format, such as weight, rigidity and pack dimensions. When these parameters change – for example, when switching to lighter or more flexible packaging – the behaviour of the product inside the buffer changes accordingly. In a pressure-based system, a less rigid pack therefore risks deformation or damage during accumulation if everything is not correctly set.

The MH Material Handling BAT Buffer operates without pressure on the product and is designed to be flexible and configurable across multiple formats and layouts. This makes it suitable even for lightweight and delicate packs.

However, flexibility does not mean that a single setup works for everything: if the format changes significantly and the buffer is not readjusted, the risk of jams and damage remains.

A useful rule of thumb during the design phase is that a buffer should hold between 2 and 5 minutes of production: the time needed to absorb the typical micro-stops of the line without losing productivity. With lighter formats, however, it is worth recalculating both the effective accumulation capacity and the discharge speed, considering that the downstream machine should be able to run at least 10–20% faster than average to recover the accumulated product.

Downstream of the packaging machine is where the real game is played

When package weight and rigidity change, the requirements of the downstream section of the primary packaging also change. All downstream mechanics – aligners, phases and lane combiners – are suddenly handling a product that is no longer matches the original design assumptions.

The packaging machine keeps running, but the downstream area – the one nobody actively monitors – is where efficiency is lost.

That is why every format change requires a check of the feeding and conveying systems, and it must be done before problems arise.

How to adapt the line without stopping production

The process starts with mapping the characteristics of the new package: weight, dimensions, rigidity and coefficient of friction.

The new format is then tested across every section of the line, not only on the packaging machine, because each section reacts differently and must be checked individually.

The most important step is to involve the conveyor supplier already during the design phase, not once the problem has already become evident.

Working in stages – validating one section at a time before moving on to the next – allows production to remain active while reducing risks.

The format changes. The line cannot stay the same

When a company decides to reduce packaging weight or thickness – whether to cut costs or to meet sustainability requirements – the decision usually starts in the purchasing department. A thinner film is selected, the price is negotiated, and the specification is updated in the system. And then it stops here.

The problem is that no one checks the impact of that change on the packaging line. The process engineer is not involved, at least not immediately. They are called in weeks later, when machine downtime starts to increase, scrap rises, and OEE drops without an obvious cause.

The machine is the same. The product is the same. However, the packaging has changed, and that change affects the entire line: from packaging to accumulation, from conveying to palletizing.

For over 40 years, MH Material Handling has been designing conveying and accumulation systems. We work on layout analysis, buffer configuration, feeding system adaptation, and the integration of new solutions into existing lines, ensuring everything works with today’s format, not yesterday’s.

If you are considering a format change, or if you are already facing issues after a reduction in material thickness, let’s talk before inefficiencies become the norm. A preventive technical discussion costs far less than a stopped line.

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Hygienic Design vs Wash Down qual è il sistema più adatto alla tua linea

Hygienic Design vs Wash Down: Which system is right for your line

It’s 6:45 a.m. The line is down for end-of-shift cleaning. The operator directs a high-pressure water jet onto the conveyor, moving the lance from left to right, then shuts off the valve.

On the surface: clean.

In reality: the frame beneath the belt has three enclosed corners where water never reaches. Organic residue builds up there, day after day.

This is not a cleaning issue. It’s a machine design issue. And the difference between a line that passes a hygiene audit and one that barely gets through – every single time – comes down to this.

Washdown: effective on paper, limited in practice

Washdown – high-pressure cleaning with water and detergents – is the most common response to contamination risks in food processing lines.

It’s relatively inexpensive to implement and provides an immediate sense of control.

The problem is that it only works if the machine has been designed to be cleaned. If the frame has enclosed cavities, if chain returns are inaccessible, if joints retain moisture, the water jet doesn’t solve the issue. It just relocates it. The result is increasing consumption of water and chemicals, longer downtime, and a real risk of cross-contamination. Meanwhile, the quality manager signs off on sanitation reports that, in practice, cannot be fully guaranteed.

Hygienic Design eliminates the problem at the source

Hygienic Design, when applied to machinery, is a design approach that starts with a specific question: how can this machine be thoroughly cleaned, under real operating conditions, with the available personnel, in the shortest possible time?

A conveyor built with this logic features open-frame construction, sloped surfaces for effective drainage, tool-less disassembly, food-grade certified chains, and materials resistant to aggressive cleaning agents.

It’s not “washable” because someone claims it is – it’s washable because there are no areas where residue can accumulate.

From an operational standpoint, the impact is significant: sanitation downtime is reduced, water and chemical usage decreases, and contamination risk is minimized. Hygiene audits become a natural outcome of the design – not a recurring uncertainty.

Not every line carries the same risks – that’s why choosing the right approach matters

In practice, the choice between a Hygienic Design approach and a Washdown system depends on where the conveyor is positioned within the line and the type of product it handles.

For unpackaged products – fresh food, meat, dairy, bakery – the contamination risk is extremely high. Here, Hygienic Design is the minimum requirement.

Monolithic belts with no internal fabric, such as the SaniBelt line we design at MH, are specifically developed for this purpose. They have no exposed textile surfaces that can retain residue and can be cleaned in just a few minutes.

When handling packaged products, still within a white area, requirements change. A washdown design can be sufficient, provided stainless steel construction is maintained and flat surfaces and enclosed cavities are avoided. In this case, tool-less belt removal for cleaning is no longer essential. Moving into grey areas, hygiene requirements can be relaxed further, with greater emphasis on robustness and throughput. Depending on the environment, you may still opt for stainless steel frames – for example, where floors are regularly washed with water – or choose anodized aluminum structures where this is not required.

3 practical steps to quickly identify critical points in your line

Before deciding whether to upgrade a single conveyor or redesign an entire section, you need a simple method to identify where the real issues lie.

Here are three key aspects to assess your current situation:

The first step is to map the line by hygiene risk level

Open product, packaged product, and transition zones. For each area, define the conveyor type and the current cleaning regime.

The second step is to inspect critical design points

Enclosed frame corners, cavities beneath chain returns, joints between modules, and moisture-prone areas. If you can’t reach a spot with a cloth, water won’t clean it effectively either.

The third step is to measure actual sanitation time

If it exceeds 20 minutes per conveyor in high-risk areas, you have a design problem. And remember: no stricter cleaning procedure can compensate for a design flaw.

A layout is designed once -but it’s lived with every day

The issue is that most companies address hygiene only when the problem is already visible: a difficult audit, a product recall, or uncontrolled sanitation costs. At that point, the room for action is limited.

At MH Material Handling, we have been designing conveying systems based on these principles for over forty years. From the Saniflex belt for high-risk areas to the BAT system with USC chain for high-speed lines, every solution starts from a real analysis of the customer’s operating conditions – not from a standard catalog. If your sanitation times are too long, if hygiene audits are always uncertain, or if you are designing a new line, get in touch. We can analyze your processes together and identify the most effective solutions to protect product safety and reduce operating costs.

Improve the efficiency of your packaging line with our MH Scan Solution
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