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Archive: February 2011




01 Feb 11

CFC Confections


Eating cotton candy without getting your hand sticky can be a challenge. On the other hand, moving and packaging cotton candy shouldn’t be a challenge — but it was turning out to be just that for Waco, Texas-based Country Fair Confections. 

Since opening its doors for business in 1992, Country Fair Confections has found a steadily growing fan base for its cotton candy, cheese corn and caramel corn. Today the confections manufacturer has grown and now sells its products in more than 40 states. 

But getting its confections out to those 40 states was becoming a problem. At issue for Country Fair Confections was a conveyor system 

“We were using a regular conveyor line, but it wasn’t a true food-grade conveyor,” said Lee Washington, president of Country Fair Confections. “It had a food (grade) belt on it, but we were dealing with rust and lots of maintenance issues.” 

[Read More...]



01 Feb 11

BreadWorks



Back in 1996 Pittsburgh-based BreadWorks significantly streamlined its Kaiser roll line by installing new equipment and automating its process. The upgrade allowed a productivity increase from 60 dozen rolls an hour up to 480 dozen an hour, all while accomplishing the job with two employees instead of four.  Supporting the processing line was a set of Dorner 6100 Series conveyors installed in 2001. However due to the nature of BreadWorks’ application which calls for daily wiping and cleaning of conveyors, a new line of Dorner conveyors is proving to be a better fit for the baking company. BreadWorks, a 25-year-old baking company known in much of Western Pennsylvania for its artisan bread and more than 60 other varieties of fresh bread and rolls, took advantage of an opportunity to replace its 6100 Series with Dorner’s new AquaPruf line of sanitary conveyors. Introduced in October 2003, AquaPruf conveyors are the first conveyor platform offered by Dorner designed solely for the food and medical industries. AquaPruf conveyors are the lowest profile sanitary conveyors on the market. These stainless steel conveyors have over-sized, sealed bearings and can take high-pressure washings with water, soap, bleach, chlorine, alcohol or foaming chlorine cleaner without the worry of bearings or other important components corroding. After more than a half year of operation, the two new AquaPruf conveyors on its Kaiser roll line are showing promising results.

[Read More...]



01 Feb 11

Dorner Application Story - Harsh Industrial Environments


-Problem

Sometimes challenging problems require new solutions. Whirlpool Corporation’s Marion (Ohio) Division was using a traditional belt conveyor in several applications. But in one situation, the conveyor wasn’t performing as well as it could. The conveyor was used under a die stamping press producing dryer bulkheads. The conveyor removed scrap, ranging from .080 slugs to pieces 7” long. Sometimes sharp scrap would get underneath the conveyor belt, cutting the belt and leading to premature tearing or breakage. Die lube would saturate the belts via the cuts, causing belt slippage, too. Belts had to be replaced frequently, up to twice a month, resulting in costly downtime and additional maintenance costs. Whirlpool turned to Dorner to solve the belt problem.

[Read More...]



01 Feb 11

Dorner Application Story - Harsh Environments


-Problem

Small parts, tight space and a harsh environment, with machine coolant and small metal chips splashing around. What’s the best way to get parts out from a CNC lathe and into a clean area? That’s what Davenport Industries needed to find. This Fort Worth, Texas firm manufactures precision eight-spindle CNC lathes that produce small turned parts, such as hydraulic fittings. The parts can range in size from 5/8” in diameter and 1” long to 1-1/4” diameter and 3” long. Space under the lathe guards was limited in terms of both width and height. The conveyor had to be durable enough to handle the wet chemical environment, too.

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01 Feb 11

Dorner Application Story - OEM Maintenance Improvement


-Problem

When you sell one of the best CNC machining tools in the world, you want your customers to be completely satisfied with the entire package. But that wasn’t happening for Hanwha Machine Tool USA of Pewaukee, Wisconsin. They are the importer and head up the US and Canadian dealer network for Hanwha, Swill-style machining tools, which are manufactured in Korea. These high-end, sliding head stock tools are used to machine small precision parts and long, small diameter parts - ranging from connectors for the telecommunications industry to medical specialty items like bone screws. Hanwha USA’s customers love the CNC machine, but weren’t as happy with the Korean-built in-feed and takeaway conveyors that came with the system. The conveyors often weren’t the exact size that customers wanted. The belts had to be adjusted almost constantly or they’d track wrong, causing deterioration along the sides. Sometimes, small parts dropped of the sides, resulting in belt damage. Fortunately, Hanwha USA found the perfect solution just a few miles down the road - Dorner manufacturing in nearby Hartland, Wisconsin.

[Read More...]



01 Feb 11

Dorner Application Story - Harsh Industrial Environments


-Problem

Indiana Automotive Fasteners Co., (IAF) occupies a four-year old facility, specifically designed to accommodate automated production techniques. Of course, dependable material conveying is key to efficient, hands-free automation. Unfortunately, IAF soon discovered that conveyors originally specified for the plant could not stand up to the rigors encountered in the plant’s manufacturing process. For instance, a plastic vibrating hopper proved to be incompatible with a variety of caustic chemical baths required in the metal finishing process. The wet, chemical environment also proved the unsuitability of a more conventional conveyor with a bearing pulley that replaced the plastic hopper.

[Read More...]



01 Feb 11

Dorner Application Story - Packaging Solution


-Problem

Boosting production by 25 percent while enhancing worker comfort and plant flexibility represented a formidable challenge for the nation’s largest faucet manufacturer. At the Specialty Division of Moen Inc.’s 250,000 sq. ft. plant in Wheeling, IL. Productivity, flexibility and ergonomics have been effectively addressed with a simple conveyor innovation.

[Read More...]



01 Feb 11

Integrator - Packaging Food


- Problem

Sometimes you can do the job in-house, but other times, it’s smarter to work with others. That’s what Kliklok-Woodman Packaging Solutions discovered. For more than 50 years, Kliklok-Woodman, of Decatur, Georgia has built forming, filling, cartoning and packaging equipment for the bakery and frozen food industry. Sometimes they design and manufacture tabletop chain conveyors for use with their equipment. Bur their new Model ECT625 glue-forming machine requires a belt-style outfeed conveyor. The machine takes flat paperboard and folds, forms and glues it to make cartons of varying sizes. After forming, the cartons drop onto a conveyor to the customer’s filling line to be loaded with product. Kliklok-Woodman considered devoting its internal design and manufacturing resources to this project, then tried to find a a compatible, dependable product at a better price.

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01 Feb 11

Dorner Application Story - Confectionery Packaging


-Problem

Combine an almost insatiable demand for America’s favorite gourmet jelly beans with a selection of over 39 flavors, and it becomes clear that the Herman Goelitz Co., makers of Jelly Belly, have to use every square inch of production space wisely. And with fourteen different packing lines running around the clock, space-saving equipment is critical to the plant’s operating efficiency.

[Read More...]



01 Feb 11

Dorner Application Story - Counting Packaging


-Problem

A CD and DVD manufacturer needed to improve the inefficiencies created by excessive manual handling on a packaging line. Downtime and low productivity were unacceptable. The application required the counting and separation of CD sleeves into groups of 25 pieces. Operators were doing this manually and needed to be freed up to manage the entire packaging line.

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