Systems-old

Conveyor Systems

What is a conveyor system? Power Pack believes a conveyor system is multiple conveyors integrated together with controls that typically include robotics. 

Power Pack has been designing and building conveyors systems for many years. It has developed a reputation for supporting integrators and manufacturers with automating manufacturing operations by installing conveyor systems that increase productivity, efficiency, and quality. With over 90 years of manufacturing experience, Power Pack offers more than material handling products, we offer engineered conveyor solutions.

A few benefits of working with Power Pack on conveyor systems include:

  • Conveyors ship fully assembled as long as the size allows for it in tranportation. This eliminates assembly time
  • Power Pack does a run-off of every conveyor. Customers are welcome to visit the facility to observe or a video of the run-off can be provided

Turnkey

Power Pack turnkey systems are a complete conveyor system that effectively provides an orderly flow of products or materials through the manufacturing process. These conveyor systems are typically integrated with controls & robotics to create a fully automated system.

  • Continuous flow or indexing conveyors move goods through the manufacturing process.  Often, this is a fully automated process with no need for human intervention.
  • Power Pack conveyors are built with a heavy-duty metal frame that supports all types of applications from automotive to recycling to metalworking.
  • Turnkey solutions are beneficial because there is a single point of contact for future modifications, maintenance and troubleshooting.
  • Power Pack turnkey systems allow workers to focus on producing goods rather than moving them from one point to another.

Storage & Retrieval

Power Pack storage and retrieval systems are used in manufacturing and distribution facilities to reduce your floor space, improve safety, and increase productivity.

  • Storage and retrieval systems work by using computer-controlled systems to automatically deposit and retrieve loads from a designated storage area.
  • Several major components make up the storage retrieval system: storage rack structure, conveying equipment, and the electrical software and hardware

Regardless of the type of system needed, Power Pack works directly with integrators, plant managers and engineers to standardize and improve production efficiency.


Case Study: Plastic Injection Molding

Customer:

A systems integrator that specializes in industrial automation 

Problem:

The standard production process was labor intensive, and the customer could not maintain adequate staffing to support its’ operation.  Their best solution was to build automation into the process. 

Solution:

Power Pack worked with an industrial integrator to design and build a system to move 30 lb. boxes loaded with plastic parts to a loading area. Boxes moved from ceiling belt conveyors to decline belt conveyors and were brought to a robotic loading area.  Empty pallets were dispensed from a de-stacker and down a chain driven drive roller conveyor to 1 of 16 chain transfer loading areas.  At that point, robotic arms stacked the fully loaded boxes onto a pallet.  Once the pallet was full, it was transported on chain driven live roller conveyors to 1 of 2 lines for shrink wrap before being picked up by material handlers. The system was designed with conveyors that run both on the floor and the ceiling to work around the existing production area footprint.


Case Study: Wastewater Treatment

Customer:

A wastewater system engineering firm at a municipal treatment plant in the southeast U.S.

Problem:

The standard production process was labor intensive, and the customer could not maintain adequate staffing to support its’ operation.  Their best solution was to build automation into the process. 

Solution:

Power Pack worked with an industrial integrator to design and build a system to move 30 lb. boxes loaded with plastic parts to a loading area. Boxes moved from ceiling belt conveyors to decline belt conveyors and were brought to a robotic loading area.  Empty pallets were dispensed from a de-stacker and down a chain driven drive roller conveyor to 1 of 16 chain transfer loading areas.  At that point, robotic arms stacked the fully loaded boxes onto a pallet.  Once the pallet was full, it was transported on chain driven live roller conveyors to 1 of 2 lines for shrink wrap before being picked up by material handlers. The system was designed with conveyors that run both on the floor and the ceiling to work around the existing production area footprint.


Case Study: Consumer Goods

Customer:

A systems integrator installing an automation production line for a large consumer appliances company.

Problem:

Existing assembly line was manual, antiquated, and inefficient. The customer wanted to modernize the production process with an automation design that improved ergonomics, efficiencies and production predictability while also eliminating an operator at the loading point.

Solution:

Power Pack worked with an industrial systems integrator and the end user to improve the design of this extensive and complex assembly line.  There were 3 different product sizes entering this assembly line from 2 different entry points.  The path varied depending on which line the part moved through, but the assembly operation was virtually identical.  Depending on the entry point, parts loaded onto either belt conveyors or chain driven live roller conveyors and traveled through both incline and decline conveyors. The height changes created ergonomic benefits for the operators who are loading/un-loading.  

After traveling through the system where robotic arms completed the assembly work, the parts moved to an inspection area for operator quality control.  If the part passed inspection, it moved onto the chain driven live roller conveyor to an existing elevator that carried it to a 2nd floor storage area.  If the part failed inspection, a pop-up transfer moved it to a repair bay.