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

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

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

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

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

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

  • Serpentine Buffer Systems

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

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

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

  • Recirculating Tables

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

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

  • Reservoir Tables

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

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

Solutions for Cylindrical Products with Special Requirements

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Beyond Savings: discover the multiple benefits of serpentine buffer systems

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

> Operational costs optimization

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

> Smart management of interruptions

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

> Operational Agility

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

> Impact on production continuity

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

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

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

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

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Optimising Packaging Spaces (PART 2)

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

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

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

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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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Product Buffers and Maintaining the Temperature, Is it Possible?

Heliflex is a particularly interesting LIFO buffer system, because it is able to resolve not only complicated buffer problems, but also address challenges regarding the product’s condition.

This conveyor system is unique in its class and it makes the system an incredibly cost-effective solution. More important still is that the system enables the cooling or heating of the goods, making it incredibly versatile in several ways.

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

Improve the efficiency of your packaging line with our MH Scan Solution
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BAT Buffer, a LIFO buffer system

BAT Buffer is a LIFO buffer system that we developed to address a series of recurring issues that have come up time and again in our two decades of industry experience.

Its uniqueness lies both in its speed, which can be regulated to ensure numerous benefits, as well as the possibility to continue or discontinue the buffer, making it possible to restore a product to the line at any time.

That makes BAT Buffer the ideal solution to absorb any inefficiencies caused by micro-stops, enabling a 10-20% recovery of productivity; by introducing the system upstream of the packaging machines, it is even possible to continue production without interruptions even if the machine stops.

Once the problem has been resolved, the product can be immediately restored to the packaging line without any further pauses.

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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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.

Improve the efficiency of your packaging line with our MH Scan Solution
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Merge conveyors: how to make the right choice

When a company needs to install a merge conveyor, there are a range of variables that make the decision a difficult one.

The need for a merge conveyor in a packaging line is itself enough to indicate a process with a very high degree of complexity and automation throughout.

Choosing the right merge conveyor means taking into account:

  • how it protects the quality of the items;
  • making sure the machines downstream work as intended;
  • the efficiency of the entire packaging line.

It is clear therefore that mistakes could be critical.
The risk of ending up with an ineffective and obsolete packaging line is too high. That is why, whenever a client asks me which model is the best fit, I always start with a thorough analysis of their current operations, needs and expectations.

So, let’s start with a quick overview of these machines, explaining their purpose, their benefits and their limitations.

To start with, there are different types of merge conveyors, but the majority fall into one of two broad categories: mechanical (or buffer) merges and dynamic merges.

Buffer merges

This product is equipped with “gates” at the entry lanes that remain closed until the convergence area is free, at which point they let the items through one after the other.

This is a simple and cost-effective solution that works as long as two conditions are met:

  • the items must be able to withstand the pressure during the buffering phase;
  • the downstream machines must be able to receive the items in a convoy without being triggered to do so.

The first point is related to the integrity of the items, and essentially means that it is appropriate only for boxes, trays and products stacked in tight packaging.

The second point requires greater detail.
As they leave the merge, the items are touching each other, or very close to it, but the speed of the conveyor belt is the same as it would be with products that space out the items with one item’s worth of space between one and the next.
The average productivity of the line doesn’t change, but when the convoy arrives downstream, the machine’s productivity at that moment is doubled.

That is why the machine must be able to manage the flow, otherwise it is necessary to regulate the flow with one conveyor belt to increase the speed and another to decrease it after the merge; however, this solution is naturally bulkier, with two more motors and a more complicated logic controller.

Dynamic merges

When handling items that cannot be buffered for fear of overlap (generally pillow pouch or flowpack packaging) or damage caused by excessive pressure or because downstream machines need the items to arrive at a regular frequency and with a certain distance between one item and the next, then it becomes necessary to install a dynamic system.

A dynamic belt merge is a scalable system consisting of a series of modulating conveyor belts that increase or decrease the speed of the items as they come through, ensuring enough space to avoid a situation where two items reach the convergence point at the same time.

With these devices, the products are always handled one at a time, thereby avoiding having groups of items together and ensuring regular spacing. As the production pace increases, the number of modulators must also increase.

M.H. is an Italian brand with thirty years of experience with handling movement and logistics within production facilities in every sector of industry, with a range of solutions for buffer systems.

When it comes to dynamic merge conveyors, MH’s fastest system isthe HP dynamic system that can reach manufacturing of up to 600 ppm for 150mm flowpacks. Depending on the weight and packaging of the items, it is possible to use up to five phases of conveyors with brushless DC motor and vacuum suction to manage rapid acceleration.

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

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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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Dynamic belt merges, how they work

It is necessary to insert a belt merge, which indicates that we’re working with a packaging line with a high degree of complexity and automation.
Process optimization is the goal, improving the packaging machine’s performance. But if you install the “wrong” system, you risk the opposite effect of having to contend with regular unplanned downtime.

When it comes to dynamic belt merges, we at MH have developed the HP dynamic system that can reach manufacturing of 600 ppm for 150mm flowpacks.


This system includes one-by-one timing of the items, created using a multi-belt system with independent power for each of the entry lanes. The machine’s control system enables oversight of the step between the packaging coming out of the system and ensures that the timing occurs without contact, removing the risk of jams, overlaps or damage.

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Dividers: the key parameters for choosing the right technology

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

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

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

Diverter or sorter? Understanding the differences

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

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

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

The 7 parameters that influence the choice

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

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

The most common solutions and when to use them

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

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

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

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

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

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

Special solutions and when they make sense

Magic Sorter

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

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

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

AIM

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

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

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

ARB

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

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

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

How to choose the right divider

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

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

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

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

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Types of conveyors: which one should you choose?

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

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

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

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

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

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Cleaning chocolate production lines: why use steam

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

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

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

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

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

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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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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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Accumulation systems: the mistake is thinking about them later

Is your packaging line inefficient? Just add a buffer and the problem is solved.

Or at least, that’s what many people think.

Adding a buffer to an existing line can turn into an expensive and unnecessary investment. Before proceeding with the installation, carefully assess all the preliminary factors: an in-depth analysis can help you avoid ending up with the same problems you started with.

To identify the most suitable solution for your packaging line, contact us: we’ll analyse your specific case and help you define the most effective solution.

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