When products need to move from a single incoming lane into multiple downstream paths, simply adding another conveyor does not solve the control problem. Product still has to be routed at the right time, remain controlled through the transition, and arrive where downstream equipment expects it. A lane diverter conveyor helps manage that transition by directing product into different lanes based on the needs of the packaging line.
At Kraken Automation, diverting is part of a broader approach to Flow Management & Routing. The 1-to-2 Lane Divert and Reject System shown here is one demonstrated configuration designed to take a randomly spaced single lane of product and route it into multiple downstream lanes. Depending on how the system is configured, the same platform can support diverting, rejection, lane balancing, and merging functions within an integrated secondary packaging line.
A lane diverter conveyor is a product-routing system used to redirect products from one incoming conveyor path into two or more downstream lanes. The purpose is not simply to change direction. The system must control when and where products move so downstream equipment receives the right product flow without unnecessary backups, collisions, or manual intervention.
In packaging automation, Divert Systems may be used to split one product stream into parallel lines, route rejected product away from good product, balance product between available lanes, bypass unavailable equipment, or create more flexible product paths between processes. The exact design depends on product behavior, spacing, line speed, downstream demand, available floor space, and the control strategy for the full line.
The 1 to 2 Lane Divert and Reject System is equipped with a high-speed automatic adjustable guide rail system. This feature allows for precise control of product flow and positioning as product diverts from a single lane to multiple lanes. The adjustable guide rails support smooth and accurate movement through the transition, helping reduce the risk of collisions, jams, or inconsistent presentation to downstream equipment.
By accommodating different product sizes and shapes, the system provides flexibility and adaptability for a range of product-handling applications. As with any Kraken system, the final configuration depends on the product characteristics, spacing, orientation requirements, line conditions, and the equipment upstream and downstream of the divert point.
One of the key functions of the 1 to 2 Lane Divert and Reject System is its ability to divert products from a single lane to multiple lanes. This enables products to be sorted or distributed to different downstream paths based on the needs of the line. In the demonstrated configuration, product can be diverted individually or in multiple counts, providing flexibility for different production requirements.
This system can also function as a Reject System, Lane Balancing, diverter, or Merge System. Those functions address different line needs: rejection removes non-conforming product, lane balancing distributes product more evenly, diverting sends product into alternate paths, and merging coordinates multiple streams into controlled downstream flow.
Bringing those functions together can be especially useful in packaging lines where downstream equipment has different availability, capacity, or timing requirements. Rather than treating the divert as an isolated conveyor component, Kraken evaluates how the routing point affects the complete packaging system.
The 1 to 2 Lane Divert and Reject System shown in this application is designed as a standalone plug-and-play system for fast integration into existing line operations. The demonstrated configuration operates using standard 120V AC power and includes compressed-air quick-connect functionality. This streamlined setup can help reduce installation complexity when the application and surrounding equipment are suited to the configuration.
For retrofit projects, ease of integration matters because the new equipment must work with existing conveyors, controls, production rates, operator access, and downstream machinery. Kraken’s focus is on fitting the divert into the broader line so product flow remains coordinated before and after the routing point.
To accommodate different production requirements, the 1 to 2 Lane Divert and Reject System offers an adjustable setup. The system can be configured around product size, conveyor conditions, and lane requirements for the specific application. This adaptability supports integration into existing line operations while reducing the need for unnecessary changes to surrounding equipment.
The conveyor elements themselves are only part of the solution. Kraken approaches Conveyance & Product Flow as part of a coordinated packaging system, accounting for transfers, spacing, elevations, line speed, orientation, and the way upstream and downstream machines interact.
The system’s intuitive Human-Machine Interface (HMI) enhances operational convenience and control. The HMI provides a user-friendly interface that allows operators to interact with the system, monitor performance, and make necessary adjustments. Additionally, the built-in recipe selection feature enables easy recall of predefined settings for different products or production runs. This simplifies changeovers, reduces setup time, and ensures consistent performance across different product variations. The intuitive HMI empowers operators to efficiently manage the system, improving productivity and reducing the risk of errors.
The 1 to 2 Lane Divert and Reject System is a versatile and efficient solution for material handling in manufacturing and processing applications. With its high-speed automatic adjustable guide rail system, multi-lane capabilities, reject functionality, and intuitive interface, this conveyor diverter enhances operational performance and streamlines production processes. The system’s ability to divert products accurately, merge lanes seamlessly, and function as a standalone plug and play unit makes it an ideal choice for businesses seeking to optimize material flow and enhance overall efficiency. By implementing this advanced conveyor system, organizations can achieve improved lane balancing, increased productivity, and better control over their material handling operations.
What is a lane diverter conveyor?
A lane diverter conveyor redirects products from one incoming lane into two or more downstream paths. It can be used for product distribution, lane balancing, bypass routing, or rejection depending on the application.
Can a lane diverter also reject products?
Yes. A divert system can be integrated with inspection or line-control logic to route non-conforming product away from the main production flow. The reject method and configuration depend on the product and inspection requirements.
What is the difference between a lane diverter and a merge system?
A diverter sends one product stream into multiple downstream paths, while a merge system coordinates multiple incoming product streams into fewer lanes or a single downstream flow. Some integrated systems can support both functions depending on the application.
Can a lane diverter be integrated into an existing packaging line?
Yes. Kraken can design divert and routing solutions around existing equipment, but the application must account for product characteristics, controls, line speed, spacing, available footprint, and upstream/downstream machine requirements.