Liquid-Filled Nonwoven Tubs

Product manipulation is a challenging feat to accomplish because there are so many variables to consider about the product, speed, angles, orientation, and rate. Recently, Pack Air Inc. took all of that into consideration and manufactured a robust Right Angle Transfer conveyor system to manipulate liquid-filled tubs with nonwoven material inside. Built for 180-degree product reorientation, this application was even more of a challenge because of the inconsistent weight distribution and product rate. Another variable included that some of these tubs might be wet; consequently, traditional Twin Chain Turners are not right for this application due to several inconsistent variables. Here’s how we successfully handled the challenge.

After the tubs are through the meter belt, they are transferred onto a Plastic Modular speed-up belt before the first 90-degree Passive On conveyor belt. Having a speed-up belt after the meter belt allows minimum gaps to be formed between each product that are necessary for a proper transfer. This Passive On conveyor was built with a special type of passive-on belt that integrates mini 45-degree angle rollers into the modular design, allowing the product to transfer at 90-degrees. 

From there, a short straight-running conveyor takes the tubs to a second Passive On conveyor belt that returns them to the same orientation as the incoming product. However, the leading and trailing edges are now reversed. The Passive On transfer conveyor discharges onto a final straight running modular belt and aligns the product with the packaging machine using a plowing guide rail.

An advantage of this custom design using the Passive On belts is that the product can move in a continuous motion on the production line without having to stop and use a conveyor device to right angle transfer the product. This allows for a consistent and reliable 180-degree turn regardless of product variables.