In high-volume manufacturing, synchronising upstream and downstream processes is essential for maintaining efficiency. This was the focus of a project for a major office supplies manufacturer that required a flexible conveyor system with integrated buffering for handling carton blanks.
The conveyor system needed to transport stacks of carton blanks in different formats, each weighing 7–10 kg. These were produced by a cutting machine at a rate of six stacks per minute. However, the cutter was located in a separate room behind a fire protection wall, meaning stacks had to pass through a fire flap before entering the main conveyor line.
A key challenge was the mismatch in production speeds. While the cutting system produced six stacks per minute, two downstream stack magazines could only process four. This required a buffering solution to decouple the processes while maintaining a steady material flow. Accurate alignment of stacks before entering the magazines was also critical to avoid errors. Additionally, the design needed to include safe crossing points so operators could access both sides of the system without disrupting production.
To meet these requirements, a conveyor and storage system around 10 metres long was developed using a modular approach. At its core is the mk RBM-P 2255 roller conveyor with a Poly-V drive, enabling both transport and buffering within a single system. This allows controlled accumulation and release of stacks, compensating for the differing speeds between processes.
mk’s KGF.P 2040.02 curved belt conveyors were added to manage directional changes within the available space, ensuring smooth handling while maintaining stack orientation. An integrated alignment unit positions each stack correctly before transfer, while pneumatic pushers move them accurately into the magazines. This coordinated system reduces the risk of jams and ensures consistent operation.
Operator safety and usability were addressed through two pneumatically operated swivel passageways. These allow safe crossing over the conveyor line, complete with cable bridges, ensuring easy access without interrupting workflow.
The conveyor system also offers flexible control through segmented drives, allowing variable speeds and start-stop functions in different sections. This is particularly useful for buffering, where precise flow control is essential. The design is easy to maintain, with smooth surfaces and minimal edges, making it suitable for clean production environments. Optional features such as high protection ratings and braking systems further increase adaptability.
Overall, the solution provides reliable process decoupling, improved safety and efficient handling. It highlights how combining modular components with customised engineering can deliver a scalable and effective conveyor system tailored to specific production needs.
As the only UK and Ireland distributor of the mk conveyors, visit AdaptTech’s website to find out more.
