3 to 1 Lane Merge System

System Highlights

  • Can achieve speeds of up to 120 PPM
  • Provides interposing delivery of pouches from a product filling station to a ‘pouch-in-a-box’ cartoner
  • Tabletop conveyors transport product between operations
  • Three lanes, each configured with six staging modules, allow for greater speeds and increased throughput
  • The Merge Conveyor is equipped with sensors that detect carton jams and backed-up product

The KAIM-120 is the beefed-up version of the KAIM-60 it functions in a very similar way with minor differences designed to provide double the throughput for faster applications.The three primary components of the KAIM-120 are:

  1. Pouch Infeed Conveying System
  2. 3 Lane x 6 Stage Indexing Module
  3. Merge Conveyor Module

Conveying Systems

Located between the pouch cooling tunnels and the infeed indexing modules, tabletop conveyors transport product (juice pouches) between operations. Segregated into two lanes, each is configured into three pouch aisles.

3 Lane x 6-Stage Indexing Infeed Module

The KAIM-120 is comprised of three lanes, each configured with six staging modules. This arrangement allows for greater speeds and increased throughput.

The aluminum frame is guarded by panels over motorized and belt transmission areas to prevent personnel injury. An overhead structure supports and houses photosensors used to detect pouches, one per stage.

The Staging module utilizes regularly-spaced o-rings in grooved shafts to act as the main transport surface for pouched product.

Each of staging modules allows product to pass from the upstream to the downstream modules only when a photoeye, in conjunction with a pre-programmed algorithm, indicates that the module immediately downstream is empty. If not, product is slowed or stopped until all of the necessary conditions have been met. In this way, the system ensures error-free packaging by eliminating empty or over-stuffed cartons.

Three of the discharge modules are activated based on a first come, first serve basis per pouch, and remain activated for a short time period to allow proper transfer of the pouch onto the merge discharge conveyor.

Merge Conveyor Module

The merge conveyor module accepts product (pouches) released by the 3-lane x 6-stage indexing infeed and guides them towards the center discharge conveyor. The Merge Conveyor is equipped with sensors that detect carton jams and accumulated (backed-up) product between the Bag-in-Box Cartoner and the downstream Carton Closer.

  • Pouches
  • Bag-in-box products

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