Optimizing Throughput: Nercon’s Integrated Controls Design Made the Difference for a Top Snack Foods Manufacturer

February 20, 2025

Running plastic bottles at rapid rates - whether empty or full - is a challenge. Their oval and round curves tend to lead to tipping and thus, reduced line speeds. That’s why a long-time Nercon customer asked us to integrate electrical controls on two new lines, end-to-end, from empty bottle unloader to filler, labeler, and case packer, to case palletizer.

“We supplied all the conveyance on this project between all the different OEM pieces of equipment,” says Ben Klubertanz, Nercon electrical project engineer. “This customer needed our electrical controls expertise with speed, timing and controlled flow to ensure the highest flow possible without bottles tipping, and that’s what we delivered.”

The Challenge: Start up two new wash-down production lines quickly

• 14 pieces of equipment per line coming from multiple suppliers, each with its own controls
• Lines would run several different products with specific “recipes” for product size, labeling, and packaging 
• Production rate goal of 400 bottles/minute
• Desire for every line component to serve up data to the customer’s SCADA program

The Solution: Integrated line design by a conveyor and controls expert

• Our electrical engineering team designed and programmed the controls system. Our team used components from partners Rockwell Automation, Banner Engineering, and LinMot, including sensors, motors, drives, PLCs, and e-stops, and fabricated the control panel in-house. The team tested the system prior to shipping.
• A Nercon electrical-mechanical engineering team assisted with the installation and performed the controls integration onsite, testing and adjusting all of the line configurations to optimize throughput
• Nercon provided all of the conveyor, including specialty equipment like the Mongoose Continuous Laner (also known as a dynamic laner), which helps maintain high throughput without product tipping or gaps in product flow 
• Nercon maximized the customer’s floor space with the line design, and integrated overhead conveyor to feed the palletizer
• Nercon’s team trained the customer’s operators to use the automated controls system, ensuring a fully-prepared team of machine operators with the knowledge to manage all the variables the lines would present during the production process

The Results: Customer satisfaction with performance 

• Two new lines started up within the customer’s timeframe by a single partner
• 95% line automation: Controls for speed, timing and flow between each machine optimize throughput and deliver data to the customer’s SCADA platform
• Production rates average 300-325/ppm – the highest rates possible given line configuration, production specifications, and nature of the products being produced. The client was extremely satisfied with the solution. 

The right combination of expertise and technology has helped this customer reach full production potential on its new lines. If you’re interested in learning more about how controls-conveyor integration can elevate your operations, get in touch with us today. Let’s talk about your customized solution.