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AS Conveyor Systems
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As Conveyors - Conveyor systems for all applications
As Conveyors - Conveyor systems for all applications

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Dorner conveyors were recently utilised by a specialist machine building company to assist a top food manufacturing company increase their packaging and cartoning conveying line speeds. There was also a desire to at the same time make more efficient use of the group of packaging personnel and materials in a particular department.

Previously, the company had been using a technique of side-loading polypropylene film pre over-wrapped oven baked goods into cartons. This process was unfortunately experiencing product line jams, requiring frequent downtime for maintenance. Because of this, the machinery was running at lower speeds than possible in order for the bakery to keep up with their current demand.

To address the problems involved with this side-loading packaging process, the customer decided to install a top-loading cartoning system using a new combination of two forming and integrated cartoning machines from a packaging machine provider and a 6M long Dorner belt conveyor.

The end result for the customer was a very welcome 20% increase in production line speed and very considerable packaging material cost saving due to the much reduced amount of product damage from line jams.

For more information on Dorner belt conveyors go to http://www.asconveyorsystems.co.uk/belt-conveyors.html
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An interesting conveyor shipped recently is pictured here.
This is a troughed belt conveyor, so called because the under plate for the conveyor has a "V" shape formed in it.
The belt, when it passes over the bed plate replicates the form of the bed and this creates a "Trough" in the centre of the belt.
This is particularly useful for loose products such as pellets or granules, that collect in the centre of the belt at the base of the V.
This is a more economical method than using side guides to retain loose products on the belt, with the added advantage that there is little or no risk of the products leaving the belt and either spilling onto the floor, or worse getting trapped under the belt, a common cause of belt wear and shredding.
The V shaped trough flattens out at either end of the conveyor so that the belt can wrap around the rollers correctly.

Troughed belts are available in all sizes for various applications at http://www.asconveyorsystems.co.uk .
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Another application example here from our friends at Dorner Conveyors which involved settling or flattening down of (In this case) pouch contents for subsequent box loading. This flattening and settling of loose products such as granules and powders can make a big difference in mass production environments where the utilisation of packaging space is critical. In this particular case the pouches arrived at the settling station in an upright orientation. The cross bar across the belt as shown pushed over the pouches so it's ready for the settling process. The package settling conveyor was servo driven and pulsed back and forth, thereby dispersing and leveling the pouch contents for further carton or box loading.

Benefits:
• Settles contents of package for efficient box packing
• Is and in line process therefore does not require a change in product flow
• Can be used with weighing or height detection equipment for leak detection
• Maintains pouch spacing

Product Specifications:
• Base Conveyor Platform: 2200 Precision Move belt conveyor
• Belt type: T10 Positive drive belting
• Mount Package: Servo motor bottom mount package
• Belt Speed: Pulse speed and duration is programmable to
best match the pouch configuration

Pouch Sizes and Product Rates:
• Maximum Pouch Width (leading edge):
» 8" width conveyor = 6" max. pouch width
» 12" width conveyor = 10" max. pouch width
» 18" width conveyor = 16" max. pouch width
» 24" width conveyor = 22" max. pouch width
• Maximum Pouch Weight: 5kg
• Maximum Product Rates:
» Minimum spacing between pouches = 12"

More details on the these Dorner precision drive belt conveyors can soon be found at http://www.asconveyorsystems.co.uk/belt-conveyors.html
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Added to the D-Tools system recently are the following belt conveyor designs:

2200 Series & 2300 Series belt conveyor additions consisting of:
Mid drive belt conveyors and mounting packages
Redesigned gravity roller conveyor (2200 series only)
Brushless DC gear motors are now available
Compact VFD gear motors are also now available
Type 73 nose bar belt (2200 series only)

All industrial product lines:
Basic VFD (Variable speed) controller
Note : Type 53 belt is now a non-stocked specialty belt

7200 series conveyor CAD will be enabled

Why should you register for Dorner tools?
Once signed up as a member, you can:
Access all Dorner conveyor design tools, including the CAD library & product configurator.
Build a complete belt conveyor assembly to your exact layout and dimensions.
Download a single CAD model (In several formats) of your entire conveyor assembly.
Eliminate the design time you might have spent assembling separate CAD models.
Reduce compatibility errors because the tool only allows matching components to go together.
Get 3D PDF files for visualization by others in your organisation who may not be CAD users.

More details on how to enrol can be found at pallet conveyors available at http://www.asconveyorsystems.co.uk .
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Shipped out last week, 3 X chain driven roller pallet conveyors with 3ph AC motors and low level stand systems.
These conveyors were built for a pallet handling application where the roller conveyor has to transport wooden pallets that weigh 1500kg when loaded.
Normally on a gravity conveyors and systems where pallets are pushed along, accumulation is simple, but for powered pallet rollers conveyors it's not so easy.
One option is to use electrical controls and sensors to stop the rollers in certain areas where a pallet is present but this will involve multiple drives for chain driven pallet conveyors.  
Through the use of driven rollers with chain sprockets and special internal roller mechanics, the pallets accumulate when they reach the yellow end stop.

More details will be available at http://www.asconveyorsystems.co.uk/Pallet-Conveyors.html soon.
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Our gravity conveyor product range with aluminium side frames and low weight rollers is popular with users who have light weight applications or who need the conveyor itself to be light weight.
These conveyors are not actually any cheaper than normal steel framed conveyors because they are produced in lesser volumes than the steel framed gravity conveyor units that we offer.
However in certain situations they have advantages over their steel framed stable mates.
Where the user is having to move conveyors around to meet production requirements, they have the option of our flexible conveyors that expand and bend, or they can use the fixed aluminium framed gravity conveyors, often fitted with castor's to make movement easy.
These aluminium fixed conveyors are significantly cheaper than the expanding roller conveyors, but they obviously are not as flexible in use.
They are also obviously lighter than their steel variants, so the effort taken to move the conveyors is much less, which can be a solution to strain injury potential in some factories and warehouses.
Rollers are available in BZP steel, with aluminium and even plastic rollers as an option.
More details available at http://www.asconveyorsystems.co.uk/Gravity-Conveyors.html
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Recently, a customer needed to convey 40 lb blocks of cheese away from their cheese processing towers to the next step in the production flow. With experience with creating belt conveyors and conveying solutions for handling cheese seemed pretty straight forward. However, like any application, once you dive deeper into what needs to be accomplished certain challenges emerge.
In this specific application held a few challenges. Here’s a look at the challenges in a problem/solution format:
Challenge: The conveyor system would have to be broken into multiple conveyors in order to handle the heavy product load of up to 420 lbs.
Solution: Any time that multiple conveyors are used, you must have to take into account the transfer points between the conveyors. To keep these transfers tight, a solid urethane positive driven belt with internal aramid tension members was chosen. This belt has limited stretch, can be run under tension, and is capable of going around a 48mm diameter transfer tail.
Challenge: Conveyors would have to be bi-directional to handle both raw and bagged cheese blocks.
Solution: The conveyor belt was driven by the proven Dorner 7600 Series AquaPruf ULTIMATE bidirectional centre drive module with 20-tooth drive sprockets.
Challenge: Minimise the product loss when conveying raw, un-bagged 40 lb blocks of cheese from cheese towers to an auger system.
Solution: A special troughed guide profile was developed to provide the customer with a troughed belt cross section, which stopped loose cheese curds from falling off the sides of the conveyor belt, thereby reducing product loss.
Outcome:
The cheese tower span was covered using two inline sanitary food grade conveyors, achieving their designed maximum load capacity of 10 cheese blocks (or 420 lbs) while running in either direction.
Product loss at the conveyor-to-conveyor transfer was greatly limited by providing a 48mm diameter, solid stainless steel idler pulley on each idler tail.
UHMW troughing guides were provided to trough both belt edges providing the customer with a conveying system that captured most all loose product on the conveyor belts. Straight guides were also provided to replace the troughed set when conveying packaged cheese blocks. The troughed guides and straight guides could be swapped out without the use of any tools, making the changeover fast, easy and sanitary.
More details will be available at http://www.asconveyorsystems.co.uk/belt-conveyors.html soon.
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The new 1100 series belt conveyor systems from Dorner are soon to be available from AS Conveyor Systems.
With a 19mm thick frame, it's one of the thinnest mass produced belt conveyors available.
And because it's a Dorner conveyor, it's the real deal, with drive options, a decent load capacity and speed capability.
We think it could be a massive success. Have a look at the video here and also the technical details below.
· A certification for Clean Room Class 100.
· A 16mm roller transfer tail for accurate and efficient small part end transfers, plus a patent-pending pinch drive that allows for a 7kg load without the need for high belt tension.
· An anodised aluminum frame with FDA-approved plastic tail plates and stainless steel fasteners.
· Availability with fixed speed AC and brush less DC gear motors, with belt speeds up to 20M/min on conveyor lengths from 38mm to 1524mm in 3mm increments.
More details will be available at http://www.asconveyorsystems.co.uk soon

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Flexmove slat band conveyors can be used in a multitude of interesting materials handling applications, but one of the more interesting ones is puck handling.
A puck is used often where the product (Normally a bottle to be filled) is housed in a puck for stability and positional accuracy.
The plastic slat band conveyor transports the puck with bottle on it's journey to be filled then emptied of the bottle before getting a fresh empty bottle.
It's a great way to use Flexmove conveyors because the pucks can be accumulated, take inclines and declines but also the product can be taken out of the puck by a "Depucker" which grabs the product from the sides and while the puck drops away on the horizontal conveyor the depucker keeps hold of the product, depositing it onto another conveyor.
Find out more at http://www.flexmove.co.uk
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A recent application from Dorner Conveyors illustrates how a standard belt conveyor can be adapted easily for a special application.
In high speed packaging and production environments, it's often very desirable to make a pouch or similar package descend or ascent in a very short space.
Normally, conveyors without flights can incline products at angles up to about 35° without too much trouble and without fallback of fall-forward.
With flights, greater angles can be achieved but flights can bring their own problems with sequencing the flights to collect the product at the right time. Also these flights require a gap at the start and end of the conveyor to allow them to rotate under the return roller.
Dorner's vertical pouch elevator was developed to satisfy and application involving the rapid incline of pouches from drop height of filling machines to working height or ceiling height.
In this system, two belts are orientated over the top of each other with the friction of the belts creating a pocket to convey the product up or down.
This solution saves floor space while maintaining pouch orientation and spacing.
The main benefits are that the system uses less linear floor space to elevate pouches and also maintains pouch orientation without crushing contents.
It also maintains pouch spacing allowing for predictable marking or labeling further down the line.
See more conveyor belt details at http://www.asconveyorsystems.co.uk/Vertical-pouch-conveyor-belt.html
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