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Through the Alba Partner Network (APN), integrators continue to find practical ways to modernize aging material handling systems while improving reliability and operational flow. A recent project completed by Innovative Conveyor Concepts, Inc. (ICC) illustrates how thoughtful conveyor design can resolve long-standing operational challenges.
The end user operates a packaging line supported by three conventional palletizers, each producing multiple case configurations and feeding pallets into a stretch-wrapping process at the end of the line. The original system relied on an older drag chain conveyor with pop-up roller transfers running down the center of the palletizers. While the system had served its purpose for many years, age and mechanical wear had begun creating frequent downtime and maintenance challenges.
In addition to reliability concerns, the existing conveyor configuration was not ideal for the range of pallet types being processed through the line. The end user wanted to transition to a roller-based conveyor design that could provide smoother pallet movement while reducing system complexity and maintenance requirements.
Designing a Better Flow |
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Working closely with the customer, ICC designed a new material handling approach built around Alba conveyor components and ICC supplied integrated controls. The line begins at the first of the three palletizers and carries pallets through the system using a controlled flow approach. ICC’s control system manages pallet traffic automatically, coordinating communication between the palletizers and downstream equipment to keep product moving efficiently.
Alba played an important role in the system’s design. One of the unique requirements of the installation was maintaining safe and efficient operator access across the line. To address this, Alba designed an operator crossover conveyor section positioned between the fourth and fifth turntables, allowing personnel to safely move across the production area without interrupting pallet flow.
At the end of the line, a 90° turntable redirects pallets into the facility’s existing stretch wrapper. ICC implemented the controls handshake between the conveyor system and the wrapper to ensure seamless communication between the two systems and maintain a consistent flow of product through the final packaging stage.
Improving Reliability and Flexibility |
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By replacing the aging drag chain system with a roller conveyor-based design, the new system provides several key advantages:
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Reduced Mechanical Wear and Maintenance Requirements |
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Improved Reliability and Uptime |
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Better Accommodation of Varying Pallet Types |
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More Controlled Traffic Flow between Palletizers and Wrapping Operations |
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Safer Operator Access within the Production Area |
For the end user, the result is a modernized pallet handling line that delivers greater operational stability while making day-to-day production easier to manage.
Partnering for Practical Solutions |
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Projects like this highlight the value of collaboration between Alba Manufacturing and its APN systems integrators. By combining integrator-level system knowledge with Alba’s conveyor engineering, customers gain equipment designed to solve real operational challenges while delivering long-term durability.
For ICC Conveyor and their customer, the upgraded system delivers smoother pallet flow, reduced downtime, and a design built to support the operation for years to come.
When you need proven conveyor solutions and expert guidance, trust Alba Manufacturing. Our team can connect you with the nearest Alba Partner Network member to support your next project. Call 866.252.2634 or visit our website at www.albamfg.com.
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