Skip to main content

M.H. – Material Handling

Luca Fontana

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
READ
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
READ
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
READ
Quanto costano sostenibilità e sicurezza alimentare

How much do sustainability and food safety cost?

If you want a system that meets the highest hygiene standards and it is also sustainable, you should know that the initial investment will be significant. But there’s good news for you…

The higher upfront cost of a safe and sustainable packaging line for food products will more than pay off — not only through long-term cost savings, but also thanks to the strong reputational advantage you’ll be able to associate with your brand.

If you’re ready to move towards a more hygienic and sustainable design, don’t hesitate to contact us: request our MH Scan Solution, an in-depth diagnosis to analyze and optimize your packaging line.

Improve the efficiency of your packaging line with our MH Scan Solution
READ
Saniflex l’Hygienic Design secondo MH Material Handling

Saniflex: Hygienic Design by MH Material Handling

Anyone working with fresh cheese, meat, fish, or ready meals knows how challenging it is to maintain high hygiene standards without compromising production efficiency. In such environments, every detail can make the difference between a high-performing line and a potential risk.

That’s why MH Material Handling developed Saniflex: a conveyor system designed to combine food safety, easy cleaning, and continuous operation.

A solution developed directly in the field, based on real industry needs

Saniflex is not a catalogue product—it’s the result of years of hands-on experience working closely with real food manufacturing environments. In facilities where cleaning must be frequent, thorough, and fast, every component has been designed to simplify sanitation procedures, minimizing time, resource consumption, and contamination risks.

Key features include:

  • open frame with sloped surfaces to prevent water stagnation and support proper drainage;
  • no blind spots, eliminating areas where residues could accumulate;
  • tool-free removable components to ease daily disassembly;
  • polypropylene chain with polyketone pins, highly resistant to common chemical cleaning agents;
  • stainless steel frame in AISI 304 or 316L, with bead-blasted or 2B finish to reduce dirt adhesion and improve cleanability.

Measurable results: less water, fewer stops, higher efficiency

In real-life installations and testing phases, Saniflex has proven to deliver tangible benefits. The system is built to handle frequent cleaning cycles—even several times a day—without hindering productivity.

Key advantages:

  • up to 50% reduction in water and detergent consumption, thanks to faster and simpler cleaning;
  • less downtime, due to quick disassembly and washing;
  • compatible with Clean-In-Place (CIP) systems and monolithic belts like Thermodrive, meeting the requirements of modern production lines.

Saniflex can be seamlessly integrated into both new installations and existing lines. Its modular design allows for high layout customization, addressing space, process, and configuration constraints. Each project is supported by MH’s technical team to ensure optimal integration and performance.

The MH approach: no off-the-shelf solutions, only tailor-made systems

At MH Material Handling, every solution starts from a real need. Saniflex is the perfect example: a system developed for those who don’t want to choose between hygiene and productivity—but demand both. With Saniflex, hygienic design is more than a feature—it’s a real added value.

Want to know if your line meets the highest hygienic standards?

Book a free consultation with MH Scan Solution: together we’ll assess your plant, identify critical points, and propose the best solutions to turn your line into a hygienic, efficient, and compliant system.

Improve the efficiency of your packaging line with our MH Scan Solution
READ
Dispositivi di movimentazione nel settore caseario Heliflex

Conveyor solutions in the dairy sector: what you need to know

If you work in the dairy sector, you understand how challenging it is to manage conveyor solutions across the entire supply chain. With almost 500 types of cheese produced in Italy, over 50 of which have EU Protected Designation of Origin status, transportation and packaging requirements are numerous and demand tailored solutions.

Dispositivi di movimentazione nel settore caseario

In this video, we focus on a crucial aspect: the importance of technology in dairy product handling. We will cover the main challenges and the most effective solutions to ensure an efficient and safe process.

If you want more information about our products or to discover how to optimize your packaging process, do not hesitate to contact us and request our MH Scan Solution—an in-depth diagnosis to analyze and improve your packaging line.

Improve the efficiency of your packaging line with our MH Scan Solution
READ
Automazione delle linee di confezionamento sfide e soluzioni

Automation of Packaging Lines: Challenges and Solutions

The automation of packaging lines represents a strategic step for companies aiming to improve efficiency, reliability, and productivity. However, to ensure the success of an automation project, it is essential to find the right balance between production goals, financial resources, and structural constraints.

M.H. Material Handling, with nearly forty years of experience in the industry, has faced and resolved numerous challenges related to the integration of automated solutions, adapting them to the specific needs of its clients. In the following lines, we will analyze three key variables that determine the success of automation in packaging lines.

Industrial Automation: The Three Strategic Levers for Efficient Innovation

Production Goals

Defining production goals with precision, such as the number of products per minute or the ability to handle micro-stops, is the first step in developing an efficient line.

Each sector has specific requirements: for example, in the confectionery industry, seasonal lines such as those for chocolate need to be optimized to work at full capacity during winter months and reduce production capacity in summer. Planning based on demand allows for optimized investments and ensures maximum return from production facilities.

Financial Resources

Investing in automation does not necessarily mean building a complete system from the outset. A scalable approach allows for costs to be distributed over time, starting with an essential configuration and progressively expanding the line’s capabilities.

This strategy reduces risks, allows for adjustments based on market trends, and facilitates the adoption of new technologies without placing excessive strain on the company’s budget.

Operational Space

Optimizing available space is one of the most significant challenges in packaging line automation. Production plants, especially in Europe, face structural constraints that make intelligent use of space essential.

Innovative solutions such as spirals, elevators, and overhead conveyors allow for vertical development, reducing floor space usage and improving workflow organization.

Space and Productivity: Turning Every Square Meter into Operational Efficiency

Effectively managing production space is not just a matter of layout but a strategic factor that directly impacts productivity and reduces operating costs.

Overhead conveyors, for example, enable smooth connections between packaging and palletizing areas without compromising ground-level accessibility. However, when dealing with unpackaged products, it is essential to keep processing at the same level and within the same environment to maintain hygiene standards and facilitate product handling.

After primary packaging, multi-level solutions such as elevators and spiral buffers can fully optimize product distribution and improve line efficiency.

How to Integrate New Technologies into Existing Lines?

Integrating new technologies into existing packaging lines is a complex challenge that requires careful planning.

Each new addition must be designed to ensure a continuous production flow and avoid bottlenecks. An often-overlooked aspect is the connection between production lines and the warehouse: poor management can cause interruptions and compromise productivity.

Additionally, adding machinery or conveyor belts must be carefully studied to avoid obstructing operator movement and to facilitate maintenance operations.

For companies that cannot afford long production downtimes, the most effective strategy is to implement automation in phases, minimizing downtime and ensuring a smooth transition.

Automation and Growth: Looking Toward the Future

Investing in automated solutions does not only mean increasing productivity but also improving safety, reducing waste, and ensuring greater operational flexibility.

A well-designed system allows companies to quickly adapt to market changes, maintaining a competitive advantage.

To successfully transition to automation, it is essential to rely on industry-experienced partners like M.H. Material Handling, which offers customized solutions to optimize every phase of the production process.

Thanks to MH Solution Scan—our advanced analysis service—we can identify the weaknesses in your packaging line and propose targeted solutions to increase efficiency and productivity.

Discover how MH Solution Scan can transform your production line and make your company more competitive. Contact us for a personalized consultation.

Improve the efficiency of your packaging line with our MH Scan Solution
READ
Sistemi di accumulo per merendine gestione efficiente delle linee di produzione

Storage Systems for Snacks: Efficient Production Line Management

The industrial production of snacks represents a constant challenge for food companies. Between the growing demand for packaged products and the need to maintain high quality and safety standards, designing efficient production lines becomes a fundamental strategic element.

One of the most effective solutions for optimizing production flow and reducing waste is represented by storage systems, which play a crucial role in managing micro-stops and ensuring operational continuity.

The Production Cycle of Snacks: From Line to Packaging

The production process of snacks is divided into multiple phases, each contributing to the creation of a final product ready for the market. It starts with primary packaging, where snacks are individually wrapped in flowpack, then moves to secondary packaging (cardboard trays) and overwrapping (multiple flowpack). Finally, the products are packed in corrugated cardboard boxes for shipping.

This articulated chain requires perfect coordination between different machines and careful management of operational pauses. Inadequate control of micro-stops can generate significant production inefficiencies. Without a storage system, excess products risk creating congestion along the line, forcing upstream machines to interrupt production.

This scenario is particularly critical for baked products, where production continuity is not only essential for maintaining the quality of the final result but also for ensuring safety. Products in transit through the oven must proceed without interruption: a belt stoppage inside the oven would not only cause burning and consequent loss of the product being processed but could create an even more serious risk. In large industrial ovens, where significant volumes of product are in transit, a blockage could lead to overheating and, in extreme conditions, even fire development, putting at risk not only production but also the safety of the entire facility.

Storage Systems: The Optimal Solution

Companies have two main strategies available to manage micro-stops: investing in standby machines or integrating storage systems.

Although the first option might seem more intuitive, it involves high costs both in terms of initial investment and maintenance. Storage systems, instead, represent a more versatile and economical solution.

A storage system consists of a conveyor belt with input and output devices, designed to manage excess products in a fluid and organized way. The versatility of these systems allows them to adapt to the specific needs of the production line, optimizing flow without interruptions. Moreover, many storage systems utilize vertical space thanks to spiral designs, reducing floor space and improving plant organization.

Heliflex: An Advanced Solution for Complex Lines

Among storage systems, Heliflex stands out as a solution specifically designed for complex packaging lines like those for snacks. Heliflex uses a unique chain, wound in a spiral around synchronized drums. This design allows for continuous or discontinuous product accumulation, with a capacity that ideally varies between 200 and 500 meters, ensuring optimal use of available space.

One of Heliflex’s main advantages is zero-pressure management, which ensures the integrity of products and packaging. This feature is fundamental for snacks, where damaged packaging could compromise freshness and aesthetic appearance. Furthermore, the system allows products to be returned to the line at any time without having to empty the entire buffer, offering unparalleled operational flexibility.

In an articulated production line like that of snacks, Heliflex is typically positioned after the tray packer, to manage micro-stops of downstream machines, such as overwrapping, case packing, and palletizing.

In more advanced lines, it’s possible to integrate additional storage systems to improve production efficiency. An example is the multi-tier buffer, positioned between the process line and flowpack machines for primary packaging. This system is designed to manage the flow of not-yet-packaged products, handling them in their “naked” form and ensuring fluid and organized management.

Tailored Solutions for More Efficient Production Lines: The Importance of Strategic Choice

Each production line has specific needs, determined by factors such as product type, line speed, and downstream machine capacity. For this reason, the choice of storage system must be carefully planned, considering not only current needs but also potential future developments.

Heliflex represents an example of how technological innovation can respond to these needs, offering a versatile and scalable solution. However, its integration requires careful planning and thorough evaluation of the production layout. For example, using spiral buffers not only optimizes space but also improves overall line efficiency, reducing downtime and minimizing waste.

With MH Material Handling, you can count on tailored solutions to optimize every aspect of your production line. Thanks to our exclusive service, the MH Solution Scan, we can thoroughly analyze your packaging lines, identifying critical areas and proposing the best alternatives to increase productivity.

Don’t let inefficiencies compromise your competitiveness: contact us today and discover how we can help you transform your production into a cutting-edge system, ready for future challenges.

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

READ
Heliflex

HELIFLEX: a unique multipurpose buffer system

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.

Improve the efficiency of your packaging line with our MH Scan Solution
READ
Produzione di cioccolato come ottimizzarla con le linee di trasporto per controplacche

Chocolate Production: How to Optimize It with Counterplate Transport Lines

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.

Improve the efficiency of your packaging line with our MH Scan Solution
READ
MH banner blog 240023 20240220 FE EN
MH banner blog 240023 20240220 NL EN

Follow us

Linkedin Youtube Facebook Icon-twitter-x

Categories

Recenti

Insights, ideas and news
about product handling

Popup Newsletter
mh smistatori

Dividers: the key parameters for choosing the right technology

A divider distributes a product flow across multiple outlets along a packaging line. One of the most common situations arises when an upstream machine has a higher capacity than the downstream machines and the flow needs to be split into multiple lanes. This is typical of high-speed and flowpack lines, at the transition from primary to secondary packaging. We have been working in this field for over forty years, across the food, beverage, pharmaceutical and packaging sectors.

On these lines, the main parameters are line speed and cadence. Beyond a certain output rate, even the fastest secondary packaging machines cannot keep up. This is the same limitation encountered with mergers.

Splitting the flow into multiple lanes also helps ensure machine reliability and durability over time. Downstream, this may mean using several product arranging units or a single pick-and-place machine operating on multiple lanes simultaneously.

Diverter or sorter? Understanding the differences

The term divider, however, covers different types of equipment. The most immediate distinction is between a diverter and a sorter.

A diverter sends identical products into different lanes without changing how the products themselves are handled.

A sorter, by contrast, can also separate products according to specific criteria. Different boxes are directed to different outlets and are not treated identically, because a particular code or product is routed to its designated outlet. From a design standpoint, a sorter consists of a straight conveyor section with lateral outlets.

The 7 parameters that influence the choice

Deciding whether you need a diverter or a sorter is only the starting point. Before comparing technologies, it is worth establishing the following:

  1. the nature of the product: its shape, stability, fragility and deformability,
  2. line speed,
  3. cadence,
  4. the number of outlets required,
  5. whether the product can be touched,
  6. whether it can withstand pressure,
  7. product dimensions.

The most common solutions and when to use them

The deciding factor is the number of outlets. The selection criteria change significantly between a one-to-two divider and a multi-lane system.

Multi-lane systems require at least a channel-system divider, suitable for products that can come into contact with one another. Because contact is permitted, the divider does not space the products at set intervals: instead, it stops them in the channel, allows them to accumulate, and then switches channels. A multi-channel solution can still be considered for fragile products, but only when it is absolutely certain that the preceding product has cleared the channel.

In multi-lane flowpack systems, we use a sequence of one-to-two dividers. The application becomes more complex when products are fragile or low-profile, with a risk of overlapping.

A flap divider moves the product by making contact with it, provided the product can tolerate this. It is limited to two outlets: to obtain more, several finger-type dividers are generally arranged in a cascade. This is the simplest and therefore least expensive solution. Essentially, it consists of a deflecting paddle, with the limitations described above.

The soft touch system guides the product gently and is used on flowpack lines where accumulation is not possible. This solution also normally operates with one inlet and two outlets.

For robust, stable products such as cartons, boxes or trays, a mechanical multi-lane divider is a good solution, directing the flow by means of pallets, mobile channels or drawers.

Special solutions and when they make sense

Magic Sorter

When a product is very flat, thin or deformable, side guides can become a problem. The product may slip between the guide and the conveyor surface and become jammed.

In these cases, M.H. uses the Magic Sorter as either a divider or a merger. Product movement is controlled by a modular chain with embedded balls, suitable for items that cannot be handled using conventional side guides.

The Magic Sorter also makes it possible to create multiple outlets with the same system. This flexibility does, however, come with a throughput limitation: in the fastest applications, it can handle approximately 120 pieces per minute, which is lower than the throughput achievable with other sorting technologies.

AIM

AIM combines a modular conveyor belt with a pneumatically actuated, recessed pusher. The system acts on the lower part of the product, moving it through contact with its side. It is therefore suitable for non-deformable items that can withstand lateral contact.

Its main advantage is washdown suitability. The pneumatic actuation system withstands frequent washing, particularly when a dedicated stainless-steel cylinder is used. AIM can achieve an indicative maximum throughput of 120 pieces per minute.

Like the Magic Sorter, AIM is not used on flowpack lines: the small size of the products prevents the balls or the pusher from controlling them properly. In this case, the limitation is related to product dimensions, not line throughput.

ARB

ARB is a solution intended exclusively for end-of-line applications, where larger products such as boxes and other packages ready for subsequent processing stages are handled. One of its most common applications is feeding palletisers.

Product size alone is not enough to determine whether it can be used. The contact surface must also be checked: the bottom of the product must be even. This technology therefore requires specific conditions and differs from the dividers used between primary and secondary packaging.

Cost is another factor in the decision. ARB requires a higher investment and would not be justified where a simpler solution can perform the same task. It is therefore considered when the product type and end-of-line application genuinely warrant its use.

How to choose the right divider

Once these points have been clarified, the most suitable technology becomes much easier to identify.

Without this analysis, there is a risk of choosing a divider based on throughput alone, overlooking product characteristics, pressure resistance and the operating environment.

At M.H. Material Handling, we design and integrate all these solutions, from mechanical multi-lane dividers and the Magic Sorter to Intralox ARB and AIM applications. We support our customers in analysing product flows and selecting the most suitable configuration.

If divider selection is still an unresolved aspect of your project, we can assess it together, considering the product, throughput and required destinations to identify the best solution.

Improve the efficiency of your packaging line with our MH Scan Solution
READ
Tipologie di trasportatori quale scegliere

Types of conveyors: which one should you choose?

How many types of conveyors are there, and how do you choose the most suitable one for a specific application?

In this episode of ConveyorU Academy, our mascot Convy asks Luca Fontana, CEO of M.H. Material Handling, who walks us through the main conveyor technologies available and the key factors to consider when making the right choice.

The most suitable conveyor depends on the type of product, the stage of the production process, and the characteristics of the line.

That’s why there is no single best technology for every application: it’s essential to find the right balance between different requirements, such as safety, speed, and the characteristics of the product being handled.

Want to improve your production line’s efficiency? Contact us and request a no-obligation MH Scan Solution consultation. We’ll help you analyze your application, identify potential issues, and develop a solution tailored to the actual needs of your facility.

Improve the efficiency of your packaging line with our MH Scan Solution
READ
Pulizia delle linee per cioccolato perché usare il vapore

Cleaning chocolate production lines: why use steam

Chocolate is irresistible. Less so when it ends up sticking to the conveyor belts on your production line.

In the chocolate and confectionery industry, sugar-based residues can make conveyor cleaning particularly challenging, especially when products move through multiple processing stages before reaching the packaging area.

At M.H., in collaboration with Steam Italy, we have developed a cleaning system designed for different conveyor configurations, from continuous-surface monolithic belts to modular plastic chains.

Different conveyor types come with different characteristics and cleaning requirements, which means they also require different cleaning approaches.

Do you have a specific cleaning challenge on your production line? Contact us: we can assess your conveyor configuration together and identify the most suitable solution.

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

READ

Categories

optimize the packaging process
Newsletter MH Material Handling en

Follow us

Linkedin Youtube Facebook Twitter

Recents