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New starwheel avoids filler rebuild at Ocean Spray

New one-gallon jug challenged a filling line at Henderson, NV. New discharge starwheel eliminated need for filler modification.

Spring-loaded fingers in two-level starwheel help stabilize a gallon jug during transfer at Ocean Spray's Henderson, NV, plant.
Spring-loaded fingers in two-level starwheel help stabilize a gallon jug during transfer at Ocean Spray's Henderson, NV, plant.

When Ocean Spray was about to introduce a new 1-gal jug with an unusual handle affixed to its side about 18 months ago, engineers at the Henderson, NV, plant discovered that it wouldn’t run well on the filling machine designated for the bottle.

“We discovered we had a problem with the radius of the discharge starwheel and the number of pockets on it,” reports Steve Daniels, who then served as technical resource at the plant. “We couldn’t make the existing starwheel deep enough to accommodate the bottle and handle without causing spillage.” Because of the handle’s side location, the starwheel had to be positioned low on the bottle, so it jostled the filled bottle.

At first it appeared the plant would need major modifications made to the filler. Not only would that cost an estimated $35ꯠ, but the plant’s production would incur at least a week’s worth of downtime while the filler was shipped back to the manufacturer to make the changes.

Even worse, Daniels says, the new package for Lakeville-Middleboro, MA-based Ocean Spray was scheduled for a rollout on the West Coast, so the plant had a production deadline to meet. “One of our engineers came up with an idea for a discharge starwheel with spring-loaded fingers that would handle the jug no matter where the handle happened to be when the bottle came out of the filler,” Daniels says. “We felt it could work to eliminate the spillage.”

Another plant worker recommended Morrison Timing Screw Co. (Glenwood, IL) because he had worked with them in the past. “He said that Morrison was particularly adept at listening to customers’ needs and providing exceptional service,” Daniels notes.

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