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Sweet Success

AES's Innovation Transforms Cookie Production Line

The manufacturer faced significant challenges in their packaging process, primarily due to the manual handling required in their cookie production. The process of manually removing baking sheets and transitioning cookies to packaging was slow, error-prone, and became a production bottleneck.

 

  • The baking process required manual removal of baking sheets, slowing down production.

  • Transitioning cookies to packaging was error-prone, affecting product quality.

  • This project represented the manufacturer's first move towards automating their packaging process.

The Challenge:

The manufacturer faced significant challenges in their packaging process, primarily due to the manual handling required in their cookie production. The process of manually removing baking sheets and transitioning cookies to packaging was slow, error-prone, and became a production bottleneck.

 

The baking process required manual removal of baking sheets, slowing down production.

Transitioning cookies to packaging was error-prone, affecting product quality.

This project represented the manufacturer's first move towards automating their packaging process.

The Solution:

To address these challenges, AES developed a custom solution to automate the removal of baking sheets, incorporating an innovative vacuum drum system into the conveyor undercarriage. This system significantly enhanced the efficiency and hygiene of the packaging process.

  • Introduced mag-drive powered vacuum drum to automate baking sheet removal.

  • The system includes two vacuum drums mounted on stands for easy maintenance and cleaning. Operators can remove and replace drums without tools.

  • The newly implemented system efficiently removes baking sheets and feeds cookies into the smart-belt infeed (Garnet) which then spaces out the cookies into the flow wrapper without manual involvement, significantly speeding up the production process.

The Results:

The transition to an automated system brought about remarkable improvements in performance. The manufacturer experienced a significant increase in production speeds, going from 160-170 packages per minute (PPM) across two lines to an impressive 200-240 PPM on a single line.

This not only solved the cookie manufacturer's production bottleneck but also marked a successful transition towards a more automated and efficient packaging solution. This boost in productivity was a direct result of the innovative solutions provided by AES, showcasing the potential of automation in enhancing operational efficiencies.

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