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M.H. – Material Handling

Efficiency improvement of the lines

Catena modulare o a tappeto La guida pratica per scegliere la spirale giusta

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

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

But be careful: not all spirals are the same.

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

Which spiral is better? It depends on your needs:

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

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

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

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

Tabletop Chain Spirals: Maximum Efficiency, Minimal Footprint

Tabletop chain spirals are designed for durability and consistent performance, even at high speeds. Equipped with roller bearings that increase load capacity and strength, they’re ideal for:

  • Packaged products with minimal sanitation requirements
  • High-speed applications requiring continuous flow
  • Compact layouts with space constraints
  • Product flow from primary packaging to palletizing

If you’re looking for maximum efficiency in a compact layout, this is the spiral for you.

Our collaboration with Ambaflex has proven the reliability of this technology—delivering top performance and optimized design even in space-critical settings.

However, be aware: this is not the right choice for environments that demand high hygiene standards.

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

Modular Chain Spirals: Sanitization and Flexibility

In more sensitive environments, where cleaning is a priority, modular chain spirals provide a key advantage.

Made from food-grade certified materials, they ensure:

  • Enhanced hygiene and cleanability
  • Design that minimizes product and water retention
  • Compatibility with unpackaged products
  • Seamless integration with ovens, freezers, or coolers

This is the ideal choice for clean rooms, post-process zones, or areas with frequent washdowns.

The Most Advanced Solutions?

Our partner Intralox offers multiple advanced options, including:

  • OverDrive – Ideal for mixed environments with semi-packaged products and freezer exits
  • SideDrive – Offers greater layout flexibility and high washdown capability
  • DirectDrive – Optimized for extreme environments, including sub-zero temperatures

Thanks to our partnership with Intralox, we’re licensed to build OverDrive and SideDrive spiral systems for our applications.

The Right Choice Comes from Real Needs

There’s no “one-size-fits-all” spiral—only the one that best fits your plant.

If you handle packaged products and need speed, compactness, and reliability, the Ambaflex tabletop spiral is a great solution.

If your environment requires frequent washdowns or delicate product handling, the Intralox modular chain spirals offer top-notch safety and hygiene performance.

A Real Case: When Hygiene Is the Priority

Let’s get practical.

One of our clients needed to install a spiral conveyor in a clean room with frequent washdowns—even though the food products never made direct contact with the conveyor.
Here, the priority was minimizing water stagnation and ensuring rapid, effective cleaning.

The solution?

A modular chain spiral, built for hygienic environments and low maintenance. A system that delivered safety, reliability, and long-term performance.

Need Help Choosing the Right Spiral for Your Line?

Let us help.

With our MH Scan Solution, we offer a free technical check-up of your production line. We’ll analyze your plant layout, identify critical needs, and propose the most effective, safe, and goal-aligned spiral system.

Request your free check-up today and discover how to truly optimize your space and product flow.

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

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

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

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

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

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

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

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

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

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

Planning Automation: Space, Ergonomics, and Logistic Connections

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

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

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

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

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

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

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

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

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

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

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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.

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

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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.

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

Optimising Packaging Spaces (PART 1)

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.

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

How to Optimize Your Current Packaging Lines?

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.

Improve the efficiency of your packaging line with our MH Scan Solution
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Immagine per POST BLOG DIRECT RESPONSE (2)

From Cooling to Primary Packaging of “Stacked” Products

Crackers, rusks and biscuits are goods that require particular care and are always packaged in a stack, one on top of the other.
Because of their form and the method of primary packaging, they require special conveyor systems.

To meet this specific need, in the phase after cooling that usually takes place on wide conveyor belts, we at M.H. Material Handling have developed a dedicated line of conveyors with a modular plastic chain system, FDA certified for use in the food industry.

Compared to traditional belt systems, this solution offers significant benefits in terms of ease of use and maintenance.

Our decade of experience has taught us how much demand there is for systems that can be easily adapted to align with companies’ packaging process and to optimise their productivity.

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

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

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

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

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

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

Contact us for a technical consultation.

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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.

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

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Convy VP1

Conveyor: much more than just a connection between two machines

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

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

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

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

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

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

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

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

Do you want to improve the efficiency of your line?

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

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

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

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

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bat buffer imballaggio (1)

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

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

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

On the conveyor, however, this means less stability.

On the conveyor, just a few microns change everything

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

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

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

The buffer that worked yesterday may no longer be suitable today

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

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

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

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

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

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

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

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

How to adapt the line without stopping production

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

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

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

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

The format changes. The line cannot stay the same

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

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

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

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

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

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

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

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

On the surface: clean.

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

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

Washdown: effective on paper, limited in practice

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

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

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

Hygienic Design eliminates the problem at the source

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

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

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

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

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

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

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

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

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

3 practical steps to quickly identify critical points in your line

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

Here are three key aspects to assess your current situation:

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

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

The second step is to inspect critical design points

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

The third step is to measure actual sanitation time

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

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

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

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

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