Buyer's Guide: Conveyors, Transports, Vacuum Conveyors for Packaging Automation

In the packaging automation industry, efficiency and precision are top of mind for operation managers who are looking at improving production time and speed up product delivery when it comes to ultimately shipping product out the door. Conveyors, transports, and vacuum conveyors play a pivotal role in streamlining operations, ensuring smooth product handling, and integrating with equipment such as friction feeders and print-and-apply labeling systems.?

This buyer’s guide will help you understand the different conveyor options available, their specific applications, and how to choose the right system for your packaging automation needs.

1. Conveyors

Overview:

Conveyors are essential components in automated packaging systems, moving products from one station to the next. They ensure a continuous flow of materials, reducing manual handling and increasing throughput.

Types of Conveyors:

• Belt Conveyors: Commonly used for moving items of various sizes and shapes. They are ideal for smooth and consistent transport, making them versatile for packaging lines.
• Roller Conveyors: Designed for heavy or bulky items, often used in cases where products are loaded and unloaded manually. They can be powered or gravity-driven.
• Chain Conveyors: Suitable for moving heavy goods like pallets. These conveyors are durable and used in more industrial packaging environments.

Key Applications:

• Transport between Stations: Conveyors move products between key points such as friction feeders, printers, labeling machines, and packing stations.
• Sorting and Accumulation: In packaging, conveyors can be integrated with sensors and sorting systems to organize products for further processing.

Considerations When Buying:

• Speed Requirements: Select a conveyor system that matches your production speed. Faster conveyors are necessary for high-throughput environments.
• Material Compatibility: Choose the appropriate conveyor belt material (e.g., rubber, plastic, metal) depending on the types of products you are handling.
• Ease of Maintenance: Ensure the conveyor design allows for easy cleaning, repair, and part replacement to minimize downtime.

2. Transports

Overview:

Transports refer to systems designed to move and position items precisely in packaging automation. These systems can include conveyor belts, indexing conveyors, or servo-driven mechanisms for more complex movements.

Types of Transport Systems:

• Indexing Conveyors: These transport products in a step-by-step manner, pausing at each station for a specific operation, such as labeling or printing.
• Servo-Driven Transports: Precision-driven mechanisms ideal for high-accuracy applications, such as placing products under friction feeders or print-and-apply labeling systems.
• Continuous Motion Conveyors: These are used when consistent product flow without stops is needed, such as in high-speed packaging lines.

Key Applications:

• Accurate Positioning for Labeling or Printing: Transports are critical in ensuring products are correctly aligned for printing, labeling, or packaging tasks.
• Feeding Systems: Working alongside friction feeders, transports help position products correctly for feeding into other machines, ensuring seamless automation.

Considerations When Buying:

• Precision Requirements: If your application requires high accuracy, such as for print-and-apply systems, servo-driven transports with precise control are essential.
• Flexibility: Consider systems that can handle different product sizes and shapes, especially if your packaging line has multiple SKUs or products.
• Durability: Look for robust systems that can withstand continuous operation without frequent wear and tear.

3. Vacuum Conveyors

Overview:

Vacuum conveyors use suction to hold and move products, especially lightweight or thin materials. They are highly useful in packaging applications where traditional conveyors may not provide enough grip or control.

Types of Vacuum Conveyors:

• Flat Belt Vacuum Conveyors: These are belt conveyors with built-in vacuum systems to securely hold items in place while moving them along the line.
• Overhead Vacuum Conveyors: These are mounted above the product line, ideal for applications where space is limited, or overhead product movement is required.

Key Applications:

• Handling Thin Materials: Vacuum conveyors are ideal for moving lightweight, delicate, or thin items such as paper, labels, plastic sheets, or blister packs. This is especially important when integrating with friction feeders, which feed items like paper, cards, or labels.
• Label Placement in Print-and-Apply Systems: Vacuum conveyors ensure the label is held securely in place while being applied by the labeling machine.
• Sheet and Product Alignment: In conjunction with friction feeders, vacuum conveyors can ensure perfect alignment of items during feeding or printing.

Considerations When Buying:

• Product Material and Weight: Ensure that the vacuum conveyor has the right suction power for your specific products. Thin materials may require different suction levels compared to bulkier items.
• Integration with Other Systems: Verify that the vacuum system integrates seamlessly with other packaging machines like friction feeders and print-and-apply systems.
• Noise and Energy Efficiency: Vacuum systems can be noisy and energy-intensive, so look for models with noise reduction features and efficient energy consumption.

4. Integrating Conveyors with Packaging Automation

Friction Feeders

• Role: Friction feeders are devices that separate and feed flat products, such as paper, cards, or labels, into the packaging system. They work best when used with conveyors that provide smooth and controlled transport of materials.
• Conveyor Integration: Conveyors help transport items into the friction feeder, and vacuum conveyors can ensure that items remain in place, especially when dealing with thin or lightweight materials. The smooth movement of the conveyor ensures consistent feeding.

Print-and-Apply Labeling Systems

• Role: These systems automate the printing and applying of labels onto products. For effective labeling, the product must be precisely positioned as it enters the label applicator.
• Conveyor Integration: Precision transport systems are essential here. Indexing conveyors can stop products at the exact point for labeling, while vacuum conveyors ensure labels stay in place during the application process, reducing misalignment and errors.

5. Key Considerations for Buyers

• Integration with Existing Systems: Ensure that the conveyors, transports, or vacuum conveyors you select can easily integrate with your existing friction feeders, labeling systems, and other packaging machines.
• Production Volume: Assess the production capacity and speed of the conveyor system to ensure it meets your current and future needs. High-speed lines may require more sophisticated conveyors with enhanced control systems.
• Modularity and Flexibility: Choose systems that allow easy reconfiguration as your production needs change. Modular systems can be expanded or adapted for different product types, reducing the need for complete overhauls.
• Cost vs. Benefit: Balancing cost with features is crucial. High-end conveyors may offer more precision and durability but come with a higher price tag. Ensure that the investment aligns with your automation goals.

What does all this mean?

When selecting conveyors, transports, or vacuum conveyors for your packaging automation line, consider factors like speed, precision, material handling, and system integration. Whether you are working with friction feeders or print-and-apply labeling systems, the right conveyor system will ensure seamless operation, reduce downtime, and increase overall efficiency. Always prioritize durability, flexibility, and ease of maintenance to get the best return on investment for your packaging line.

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Article By Wayne Thompson