M.H. – Material Handling

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Produzione di cioccolato come ottimizzarla con le linee di trasporto per controplacche

Chocolate Production: How to Optimize It with Counterplate Transport Lines

In the world of chocolate production, efficiency and process quality are essential to meet the expectations of an increasingly demanding market. This need has become even more pressing due to the significant rise in cocoa prices in recent years, pushing companies to optimize every stage of production to remain competitive and profitable.

Among the systems that ensure smooth operations, counterplate transport lines play a crucial role. These systems, designed to support product handling across various production phases, are a prime example of how industrial engineering can enhance performance and reliability in manufacturing processes.

This method is particularly suitable for “hollow products” such as chocolate eggs, bunnies, and other molded figures, as well as pralines—especially irregularly shaped or spherical ones. Given their shape, these products can roll erratically on traditional conveyor belts, making counterplates the ideal solution to ensure proper positioning and stability throughout all production phases.

From Molding to Packaging: How Chocolate Delights Are Made

The chocolate production process is divided into several interconnected stages, all optimized by counterplate transport lines.

1. Molding and Stabilization

The process begins with molding, where raw material is poured into molds to achieve the desired shape. Once solidified, the product is transferred onto counter-molds—mirror structures that ensure product stability and integrity. These counter-molds, known as counterplates, are essential for securing and organizing products during subsequent processing phases, contributing to a smooth and efficient production flow.

2. Feeding the Packaging Machines

At this stage, the counterplates, with products securely nestled in their cavities, are transported to the packaging machines. Here, automated systems like Cartesian or anthropomorphic robots pick up the chocolate pieces for primary packaging. This phase does more than protect the product: the packaging is also designed to enhance the chocolate’s visual appeal, making it ready for distribution and sale. Counterplate transport lines play a vital role in managing flows toward multiple packaging machines, preventing bottlenecks with accumulation systems that reduce waste and ensure operational continuity even during machine downtime.

3. Recycling Counterplates

Once the product transfer is complete, the empty counterplates are reintegrated into the production cycle. Tipping and shaking systems ensure no residues remain, while the return process often takes place on separate levels to optimize space. Before demolding, buffer systems regulate product flow to maximize efficiency.

Advanced Solutions to Optimize Production

In addition to ensuring product transport, counterplate lines incorporate innovative devices that improve efficiency and versatility.

  • Elevators: Lift the plates for precise positioning on the transport line.
  • Buffers: Accumulate products to prevent interruptions in the production flow.
  • Tippers: Flip plates for correct positioning at each phase.
  • Bypass Systems: Temporarily redirect flow to maintain production continuity.
  • Alignment Devices: Ensure every chocolate piece is perfectly oriented for packaging.

Why Are Counterplate Transport Lines Essential?

These systems not only guarantee the final product’s quality but also optimize resource and space management. They help maintain high hygiene standards, minimize waste, and increase overall productivity. Their ability to adapt to various production needs makes them indispensable for chocolate manufacturers.

Optimize Your Production Line: Discover MH Solution Scan

In such a complex production environment, planning and optimizing transport lines are key to maintaining a competitive edge. The MH Solution Scan is the ideal solution: an advanced diagnostic service designed to analyze every aspect of your packaging line in detail. This tool identifies critical areas, proposes customized solutions, and ensures that every production phase is optimized.

Don’t let inefficiencies compromise your production: contact MH Material Handling to learn how we can help you transform your line into a cutting-edge system, ready for the challenges of the future.

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

Improve the efficiency of your packaging line with our MH Scan Solution
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BAT BufferBiscuits04

Buffer System: Which to Choose?

Let’s start with a premise: buffer systems can make a difference to the line’s efficiency.
The choice of model depends on various considerations (including financial ones) but there are three variables that must be kept in mind.

It is only by carefully considering these factors that we can move to a rapid consideration of the investment in the purchase of a buffer.

With MH Buffer Systems, you will no longer have to worry about inefficiencies. Take advantage of our expertise and technology to become a reference for efficiency in your sector.

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unificatori pneumatici

When to use Buffer Merges

he first questions that we have to ask ourselves in these situations are: Are my packaging machines suited to this system? Can my goods be conveyed using this type of merge?


Buffer or mechanical merges are equipped with “gates” at the entry lanes that remain closed until the convergence area is free; once the gates have been opened, these release the products through one after the other.

If you want to find out more about our products or to discover how you can optimise your packaging process

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Come scegliere il sistema di accumulo piu adatto

How to choose the right storage system for your business

Throughout my career, I have often come across companies who make the mistake of underestimating the importance of the packaging line of their products dei loro prodotti.

The result: Reduced efficiency and the risk that machines may not work at maximum capacity, or worse still, grind to a halt.

These situations happen because someone erroneously thinks that product packaging requires buying the primary and, if necessary, secondary packaging machines and nothing more, failing to take into account the systems necessary to connect them.

There is an image that often comes to mind when I have to tackle this kind of problem: I think of the conveyor belts like the circulatory system that carries blood around the body and allows the different organs to function. Different packaging machines have to be connected to each other by an efficient “circulatory system” that is able to iron out any discrepancies that may exist between them.

Underestimating the importance of this “circulatory system” can result in production problems and delays.

When would we need a storage system?

There are two situations in which storage systems are critical:

  • when we need to compensate for operating differences between two machines that are connected in series;
  • when we need to regain productivity during micro-stops of downstream machines.

The first condition typically occurs when an intermittent machine is connected to a continuous one; for example, when an upstream machine produces product groups at regular intervals, while the downstream machine requires an ongoing flow of products equidistant from each other.

In the second case, on the other hand, we have start-ups and shut-downs of two machines that are incompatible with each other.

In these cases a buffer is a simple solution that requires a few metres of conveyor belt to regulate the flow and avoid regular stoppages in the production process.

As you can imagine, the efficiency gains are significant.

Which buffer to choose?

The choice of system depends on various considerations (including financial ones) but there are three variables that must be kept in mind:

  • the operating method of the storage system;
  • the available storage space;
  • the recovery capacity.

It is only by carefully considering these factors that we can move to a rapid consideration of the investment in the purchase of a buffer.

How the buffer works

The buffer can either be LIFO(Last In First Out), in which, as the name suggests, the first product to enter the buffer is the last one to leave it, or FIFO (First In First Out), in which the first product into the buffer is the first one out.

Among FIFO systems, there is a choice of:

  • machines that are external to the production line;
  • machinery that keeps the product within the production line, gradually increasing the available transportation space. In the latter case, the product is fully traceable, and it is considered more of an advanced storage system rather than a buffer.

LIFO buffers are the cheaper and simpler models. They are particularly suited to non-perishable, with long expiry dates, that can wait a long time for final packaging.

FIFO systems, on the other hand, are recommended for fresh products that must pass through the packaging line within a limited time frame in order to retain their freshness. These machines are usually more complex and their price is often not far off that of the packaging machines themselves.

Storage space

The decision regarding the dimensions of the storage space is linked to the efficiency of the upstream and downstream packaging machines and the time it takes to bring them back online in cases of micro-stops. In cases of a longer stop caused by mechanical failure, it is unlikely that a system within the packaging line will be sufficient to avoid any interruption at all.

In most cases, the storage space can correspond to a production time of 2-5 minutes; obviously there may be situations in which the demand for storage is notably higher and in this case it is worth considering the cost-benefit analysis and the impact that the buffer’s presence might have on the time it takes to bring the packaging line back online.

Often, the long time to recover from a micro-stop is because the operator is unable to focus exclusively on fixing the problem, because the upstream products continue to arrive, with the potential for pressure and chaos along the line.
Real-world conditions have shown that the presence of a buffer can help to contain machine downtimes.

Another example might be whereproducts travel a long distance along the packaging line and the client wants the ability to fully empty them. In this case, the necessary space can rise to 20 minutes or more. Such situations are rare but can happen.

Recovery capacity

A properly sized packaging line requires a buffer that is able to recover the product during regular production. The downstream machine must also be able to work at a rate greater than its nominal one, usually 10%-20% faster.

The time for emptying the buffer depends on this recovery capacity.

For more information on this subject, I have published a video dedicated to choosing the right storage system.

M.H. is an Italian brand with thirty years of experience with handling movement and logistics within production facilities in every sector of industry. We offer dedicated solutions for LIFO and FIFO storage systems, tailored to the client’s needs.

Our wealth of experience and our innovative and technologically advanced solutions mean that M.H. is also able to support companies in optimizing and streamlining their packaging lines.

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

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Heliflex

HELIFLEX: a unique multipurpose buffer system

If you are looking for a multipurpose buffer system that can be used in different situations, Heliflex is definitely the right solution for you.

Today I decided to focus on its most classical use, i.e. as a ‘simple’ buffering system, from how Heliflex works to the products for which it is most commonly used.

Thanks to both its cylinders rotating in sync, Heliflex is a very cost-effective system: in fact, it enables the buffer of a higher number of items within a smaller space, thanks to its single motor.

If you would like more information on this multipurpose buffer system and would like to find out if it is right for you, do not hesitate to contact us and ask for our MH Scan Solution, an in-depth diagnosis to analyse and optimise your packaging line.

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

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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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!

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

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