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M.H. – Material Handling

Luca Fontana

Innovazioni alimentazione pallettizzatori tendenze attuali e futuro

Innovations in Palletizer Feeding: current trends and future

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

From Limited Slip Rollers to Modular Chains

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

Modular chains ensure:

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

Aerial Lines: An Increasingly Popular Strategy

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

This is because the advantages of overhead lines include:

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

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

Feeding Lines with Automatic Format Change: The New Frontier

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

Automatic format change allows for:

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

Advanced Solutions from MH Material Handling to Optimize Your Production

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

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

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Sostenibilità nel packaging alimentare un equilibrio necessario1

Sustainability in food packaging: a much needed compromise

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

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

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

Paper vs plastic: the technical challenges in food packaging

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

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

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

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

The evolution of packaging machines for sustainable production

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

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

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

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

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

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

Saniflex is characterised by the following features:

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

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

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

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

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Automazione delle linee di confezionamento opportunità e sfide nel packaging secondario (1)

Packaging line automation: opportunities and challenges in secondary packaging

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

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

Automate to reduce costs? Not so simple

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

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

Attention to space: automation requires planning

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

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

Warehousing and logistics: connection is key

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

Focus on operator safety

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

Gradual automation: a strategic choice

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

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

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

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

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

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Nastri trasportatori sanificabili

Sanitary conveyor belts: what you need to know

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

Take care to install conveyors with two primary specifications!

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

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

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Come rendere la tua linea di confezionamento efficiente e anche sostenibile

How to make your packaging line efficient and sustainable?

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

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

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

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

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

The role of accumulation systems in the sustainability of lines

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

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

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

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

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

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

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

Conclusion

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

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

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dispositivi di manipolazione prodotto

What to know about product handling devices

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

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

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

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

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

When to resort to a product handling device?

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

A few Tricks to improve efficiency on Packaging Lines

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

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

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

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

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

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accumulo prodotti cilindrici

Maximize capacity, minimize damage: A guide to buffering systems for cylindrical products

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

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

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

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

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

  • Serpentine Buffer Systems

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

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

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

  • Recirculating Tables

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

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

  • Reservoir Tables

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

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

Solutions for Cylindrical Products with Special Requirements

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

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

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

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

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

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

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

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

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

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

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

Production agility: How serpentine buffer systems maintain the flow of your products

Serpentine buffer systems are among the most traditional methodologies utilized for managing the accumulation of cylindrical products, distinguished by their ability to facilitate an agile and uninterrupted production flow of vials, cans and bottles.

These systems, comprised of a choreography of conveyor belts arranged side by side and oriented in opposite directions, maximize available space and ensure a smooth transport of products.

Precise management of the conveyor speeds allows for maintaining an appropriate interval between moving items, preventing unwanted accumulations and ensuring a balanced work pace.

These systems are designed to ensure that, in the event of slowdowns, products start to accumulate on the last conveyor belt until a control photocell detects the critical point, triggering a stop. This prevents the risk of congestion and damage, preserving the fluidity of production with a controlled and manageable pause.

Once downstream operations are restored, the conveyor belts restart with renewed energy, accelerating movement to quickly clear any accumulated buildup and swiftly reestablish the usual pace of the line. Thanks to this strategy, production can resume its rhythm with the assurance of a system that minimizes downtime and protects every item in the production chain.

Beyond Savings: discover the multiple benefits of serpentine buffer systems

The benefits of spiral accumulation systems are numerous and have a direct impact on the packaging line and operational costs. These systems are notable for their disarming simplicity and innate ability to maximize efficiency without excessively burdening the budget.

> Operational costs optimization

The structural simplicity of serpentine buffer systems translates into a significant economic advantage. Their installation requires a moderate initial investment and, thanks to straightforward maintenance, operational costs remain low over time. Additionally, their durability and reliability ensure a rapid return on investment, making them a cost-effective solution in the long term.

> Smart management of interruptions

In the event of unexpected shutdowns, serpentine buffer systems demonstrate their strength: their ability to agilely manage these moments reduces the risk of prolonged and costly stoppages. There is no need for drastic measures such as completely halting the line; instead, the situation can be resolved with minimal impact on overall productivity.

> Operational Agility

One of the most valued features is the ability of serpentine buffer systems to “empty” upstream machines. This allows the machines to keep operating even when part of the line is inactive, preventing delays from accumulating and turning into additional costs for the company. Production can thus continue more smoothly, handling interruptions with great flexibility.

> Impact on production continuity

The implementation of serpentine buffer systems ensures superior production continuity. These solutions, while simple, support a consistently operational assembly line, maintaining high quality standards for the finished product.

Now that you have explored the strategic advantages of serpentine buffer systems, you may be wondering how to effectively implement them in your production environment. Choosing and optimizing an accumulation system requires a thorough and personalized analysis of your operations, a task that goes beyond simply selecting a technological solution.

At MH, we offer not only our extensive range of serpentine buffer systems but also exclusive access to the “MH Solution Scan.” Our advanced diagnostic tool evaluates your specific production needs, identifying areas for improvement and recommending the most effective implementation for your packaging line.

To discover how the MH Solution Scan can transform your production process, click below.

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MH ottimizzare spazi 2 bat vertical

Optimising Packaging Spaces (PART 2)

As I mentioned in a previous video, the need for space is widespread and extremely common. In the last post, I spoke about the benefits of spiral conveyors over traditional conveyors. Today, I’d like to focus on a few alternative solutions.

The bucket elevator belts, intermittent or continuous cleated belts and BAT-Vertical are relevant only in specific situations, and their maintenance costs are higher than those of spiral conveyors; that is why we recommend installing spiral conveyors whenever possible.

If you also have this type of need, do not hesitate to contact us; we are able to create any type of buffer system between packaging machines, paying particular attention to specific production needs, such as optimizing packaging space in a production facility.

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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.

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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.

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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.

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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.

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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.

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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.

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