M.H. – Material Handling

Efficiency improvement of the lines

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

The Heart That Keeps Your Line Alive

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

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

Precision Control, Down to the Millimeter

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

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

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

Recover What You Thought Was Lost

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

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

Engineered to Fit, Wherever Needed

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

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

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

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

See It Live

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

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

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

But be careful: not all spirals are the same.

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

Which spiral is better? It depends on your needs:

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

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

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

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.

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

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

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

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

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

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

Planning Automation: Space, Ergonomics, and Logistic Connections

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

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

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

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

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

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

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

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

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

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.

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.

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.

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.

I’ve been involved in product conveyor systems for years now, and one of the most frequent recurring challenges is space. Companies often contact me because they need to “find” space so they can optimise their production.

It is critical to start by accurately surveying the site to understand the state of play and evaluating all necessary factors. Only after that can we evaluate where in the production line it is possible and beneficial to install a device that will help to optimise the space, as well as determine the type of device to use.

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.

On this blog, I often discuss packaging process optimization and the machinery that can be installed to achieve this goal. Designing a line from scratch, perhaps even with ample space available, is one thing; intervening on an existing line with its mechanisms already in motion is another.

Is it still possible to optimize the process in these cases? Good question! The answer is yes, but there are multiple paths to take.

Today, I want to outline some solutions to this issue because more and more companies already have a packaging line but need to make it more efficient, both in terms of performance and ergonomics.

Recently, we’ve encountered many with this problem… just think of the contacts we made during Cibus Tec at the end of 2023.

What do these production realities need?

  1. To gain space in facilities where square meters are limited and often fully utilized.
  2. To increase packaging speed.
  3. To free up floor space and develop the process vertically (returning to point 1).
  4. To make the phase from primary to secondary packaging more efficient.
  5. To adapt to changes related to seeking greater sustainability in processes.

What are the solutions in these cases?

T o create overpasses and free up floor space, some technologically advanced solutions can be introduced, such as:

  • Operator passages with gate-opening belts;
  • Retractable systems;
  • Spiral conveyors.

I want to focus on spiral conveyors because, in these cases, I consider them a valid solution.

It’s no coincidence that at Cibus Tec 2023, we presented the SVn-Bare lightweight spiral in collaboration with Ambaflex, specifically designed for agile aerial connections between primary and secondary packaging with significant economic advantage without compromising on quality and achievable peak speeds.

Another “powerful weapon” to improve the efficiency of packaging lines is represented by buffer systems; at MH, we can’t talk about them enough because they can really make a difference.

Buffer systems, for example, allow for:

  • Compensating for operational differences between two machines connected in series;
  • Regularizing the flow and preventing the processing line from constantly stopping;
  • Recovering productivity in the event of micro-stops on downstream machines.

However, integrating a buffer system at a later stage into an existing line is not straightforward; this operation requires significant attention and a series of specific evaluations regarding the performance outcomes to be achieved.

Adaptations to environmentally friendly packaging.

Another highly topical issue leading companies to plan a series of investments to modify their packaging lines is the need to adapt to the use of low-environmental-impact packaging.

When I talk about “low-environmental-impact packaging,” numerous possibilities open up that include solutions aimed at reducing packaging material or actually replacing plastic with paper, cardboard, or compostable material.

In these cases, the packaging process must keep up with progress. And keep in mind that companies will increasingly have to deal with changes imposed by a search for sustainability in processes.

To this end, at M.H., we are continuously investing in research and development of products capable of offering customers innovative and sustainable solutions in line with new market needs and regulatory requirements.

For example, the Sani-Flex hygienic design transport system, our standard for the transport of naked products, is specifically designed to meet stricter regulations; Saniflex takes into account the sanitization needs of some products to help reduce bacterial load during the process.

Another example is our partnership with Intralox for the construction or development of special products such as spiral elevators, ThermoDrive belts, and passive ARB conveyors.

These mentioned are just some of the solutions designed by M.H. to support companies in the process of modernizing their packaging lines.

If you also need to make your lines more functional and efficient, do not hesitate to contact us; we will guide you on a path to optimizing productivity specifically tailored to your needs.

Insights, ideas and news
about product handling

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

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

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

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

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

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

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.