If you were to take an overhead photo of a packaging line, the conveying system would look a lot like a highway or, in some cases, a roller coaster.

Referred to as "intelligent bridges between islands of automation," conveyors are key components to a smooth running packaging line. The idea, obviously, is to get packaging elements from point A to point Z in the quickest and most efficient way possible.

Selecting the optimum conveyor system is dependent on your packaging operation. Flat-top chain is the most commonly used style of conveyor in packaging operations and is available in several generic styles including channel frame, sanitary and open frame conveyors. But sophisticated conveyor systems are expanding beyond the generic and improvements are being made while using established conveying technologies (see our list of conveyor manufacturers at the end of this article).

Some technological improvements in conveyors include:

* Convenient and ergonomic solutions.

* Easy belt reversal for inclined conveyors to increase productivity.

* Screw style conveyors to protect products while cutting costs.

* Improvements in bucket conveyor system for handling and packaging bulk materials and powders.

Considering ergonomics

Ergonomics are a key driver to newly designed bi-directional product conveyors and accumulation tables. These units allow packers to control the amount of product accumulated while controlling conveying speeds.
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For instance, some units have variable-speed motors and speed differential belts, allowing the belt closest to the packer to be slowed down by 30%. Because packers are in control of conveyor speeds, they don't have to wait for product and accumulation is more consistent and easier to handle in less floor space. Angle-adjustable tabletops and adjustable heights are also more ergonomically sound because packers don't have to bend or stretch to reach product.

Many of these conveying systems have a pedestal style base and small footprints--varying widths from thin profiles of 65 millimeters and up. Smaller footprints help conserve premium plant floor space and are flexible enough to integrate between packaging line stations. Units are available with longer conveyor decks when multiple packers--manual or automatic--are required.

Inclined conveyors used in the food and beverage industries that are designed to operate in an upward direction sometimes need to be unloaded due to power outages, downstream back-ups or jams. Consequently, it may be necessary to reverse inclined conveyor direction, which can take physical effort and waste time.

Conventional belt drive motors have an internal backstop device that prevents the belt from roll back or reverse direction. If there is stoppage, unloading the belt must be performed manually, which results in costly downtime and undermines worker safety.

Devices are available that help reduce time and costs associated with having to reverse belt direction. For example, there is a patented Manual Release Backstop (MRB) available that has the ability to disengage an internal backstop allowing the drum motor drive to move freely in the reverse direction so the belt can be easily unloaded. The MRB can be installed on new and existing inclined conveyors. With the MRB, turning a cap screw counterclockwise disengages the backstop allowing the belt to be reversed either manually or by reversing the motor. The device is operable from the shaft opposite the junction box for simple and safe access.

Moving products safely

Transporting pharmaceutical and food powders to fill packages can be challenging and costly. Increasing requirements for dust-free powder handling have led packagers to look beyond conventional methods of powder transfer.

Compared with manual and forklift transporting and dumping of bulk material from drums or other containers, flexible screw conveyors can reduce personnel requirements significantly, especially if the material needs to be measured volumetrically where human error is possible. A screw conveyor's only moving part is its flexible spiral. It is driven by an electric motor and rotates within an outer tube, which protects product from plant debris and dust.

A flexible screw conveyor has none of the internal moving parts, crevices, filters and other potential contamination sources that can trap particles, or prevent thorough, rapid cleaning. By removing the clean-out cap, conveyor cleaning is done by flushing with steam, water or air. The screw and outer tube are also removable for wash down.

And, compared with other types of conveyors, a flexible screw conveyor can be less expensive. Fewer parts mean less wear, breakdown and, ultimately, a reduction in maintenance. Screw conveyors do not require the filters, cyclone separators, internal bearings and numerous moving parts found on conventional conveyors. Lightweight and compact, a smaller flexible screw conveyor can be mounted on frames with casters and support beams for in-plant mobility, reducing the cost of multiple stationary conveyors