Automating Snack Bag Line Cuts Labor Costs by 40%

Featuring controls from Rockwell and patented servo-driven dual-jaw technology, Viking Masek calls the Velocity the “Fastest VFFS Packaging Machine in the World.” It’s capable of production speeds to 300 bags/min. The unique center-mounted filling tube and naturally counterbalanced sealing profile are designed to provide vibration-free, extremely smooth operation at all speeds. The machine is also versatile, producing packages as small as 60 x 90 mm (0.66 x 3.54 in.) or as large as 300 x 1000 mm (11.8 x 39.37 in.). Its versatility was appealing in Darlington’s case as the firm produces bag sizes ranging from 4.25 x 5.5 in. to 8 x 10 in.

Integrated into the Velocity bagger is a continuous ink-jet coder from Linx that marks each bag with date code information. The bags are sealed shut and drop onto a Z-shaped takeaway conveyor supplied by Multi-Conveyor. The finished bags pass over a Yamato CSJ22L-00/CE31 checkweigher to ensure accuracy before dropping from the Z-shaped Multi-Conveyor and through the basket of a batch gate from AS&E right into a waiting case below the gate. Inside the basket is a light curtain, so each time a bag drops through that curtain it gets counted. When the correct number of bags has been counted, a signal is sent to the controller of the Velocity bagger and that controller sends a signal to the batch gate to close long enough for the filled case to be conveyed away and for a fresh case to be conveyed in. With the fresh case in place, the batch gate opens and bags continue dropping into the basket for the next batch.

One minor feature worth mentioning is that when a case is being filled, a pair of vacuum cups attached to pneumatic devices attach themselves to the bottom sidewall of one side of the case and stroke constantly in and out. This bit of agitation ensures that the pouches are spread evenly across the case rather than grouping all in one part of the case.Corrugated cases are erected on this system and sent on a roller conveyor that brings them to one of two right angle conveyor spurs, each leading to a batch gate that counts bags into cases.

As for case erection, it takes place not far from where the two AS&E batch gates are located. A Veritiv Lantech C-400 erects corrugated cases from flat blanks. It puts them on a roller conveyor that leads to two right angle conveyor spurs. Each of these spurs leads to an AS&E batch gate, and cases move into these gates based on demand. Once a case has received its batch of bags from a batch gate, it’s carried away at another right angle on a roller conveyor that takes cases in a single file to a Veritiv Lantech CS-300 case taper. A short distance later the cases pass through a Foxjet ProSeries Trident ink-jet printhead controlled by a Foxjet Marksman Matrix controller. As finished cases reach the end of the line, they are stacked manually onto pallets, and the pallets are then moved to a storage area where they await their journey to schools, daycares, and health care facilities across the country.

This entire snack packaging line was set up, tested, and perfected at Viking Masek’s US headquarters in Oostburg, Wis., before it was even loaded on a delivery truck.

Trial run

"Before delivery of our automation, I took my plant engineer to Viking Masek to see the system’s capabilities, slow-motion videos for assessment, and a trial run of the line before it shipped with everything labeled the way we needed it to be,” explains Schweiss, who adds that he was quite impressed with Viking Masek’s comprehensive testing and checkout process.

Viking Masek assembled the entire system onsite at Darlington Snack’s plant. The new snack packaging lines fit seamlessly into their packaging configuration, resulting in precisely the solution their customers were asking for.

“We didn’t have to worry about integration because Viking already took care of that for us,” comments Schweiss. “We bought it as a complete system and it’s functioned perfectly since.” Darlington Snack’s biggest victory with the automated packaging system is the accuracy of the batch gate–they report it’s consistently spot on.

“The real trick for me was the downstream stuff to be able to make the counters work right,” explains Schweiss of the accuracy of their packaging line. “We had to be able to get the cases erected and into the two stations in the right sequences at the right time, and then on out to the palletizing operation. It has worked seamlessly.” Today, Darlington’s packing operation, case conveyance, and case closing are all automated. Staff members who formerly were required to conduct such operations have been relocated to other areas of the facility. Since embracing automation, Darlington Snacks has seen substantial improvements with the throughput and labor-related challenges they were facing.

“Automation has cut down on our waste, overpacking, and amount of giveaway,” reports Schweiss. “It has made our customers’ experience better because we’re not coming up short on products. And I’m pleased to report we’ve doubled production with about 40 percent less labor on the line.”Shown here is one of the two conveyor infeeds leading to the batch gate counter.

As a single-source provider, Viking Masek takes care of everything, from sourcing the packaging line components, to assembly and testing, to delivery and setup, and finally technical support of the entire system.

“Viking Masek helped us tremendously as a single-source provider for the entire line. Our post-sale support has been beneficial and responsive. When we have an issue, Viking Masek takes care of it,” comments Schweiss. “I’d definitely recommend Viking Masek to anyone looking at automating their packaging operation. The fact that I’ve worked with Viking Masek in the past and wanted to work with them again demonstrates how much I value their expertise.” PW