A Plus Industrial Installation has installed industrial manufacturing systems for the Automotive, Food & Beverage, Pharmaceutical, Baggage Handling, Building Products, Paper Mills, Aerospace, Medical, Bulk Material Handling and Packaging industries since 1981.
Descriptions for Equipment Installation
Agitators are used in a variety of industries which utilize mixing tanks as part of their process. A brief list of products made using an agitator are ice cream, yogurt, other dairy products, sauces, fruit drinks, pet foods, pharmaceutical compounds, as well as numerous other applications. They generally will have a drive and gearbox which is mounted on top of a tank, or a framework mounted above a basin. A long shaft extends down into the mixing tank and has a variety of blades, or impellers, that mix up or agitate the ingredients. We have installed agitators in the food and beverage industry, wastewater treatment facilities, and for the building products industry.
Bagmakers are used in several different industries, but the most common use is in the snack or food packaging industry (potato chips, crackers, salad, nuts, confectionary, fruits, etc). They are mostly used in conjunction with a Multihead Weigher. The weigher will drop a precise amount of product down to the bagmaker, which uses a vertical fill, form, and seal technology. A roll of tube, preprinted with the manufacturer’s label and nutritional summary is fed over a former. In a swift motion, the product is dumped into the tube and the bagmaker seals the bottom and the top of the bag, producing well over 150 bags a minute for many products.
Ninety five percent of all beer and soft drink cans in the United States are made of aluminum. Bodymakers are a part of the process. Aluminum arrives at the facility on massive rolls and loaded onto a machine called an Uncoiler. It is then fed into a Cupping Press which makes a cup, or sometimes called puck, probably because it resembles a hockey puck. The cup is then transferred via conveyor into a Redraw Press (more commonly known as a Bodymaker). The Bodymaker forms the shape and approximate height of the can. The final height is provided via a Trimmer. Cans are then printed on with the end user's brand and packaging information and then go into a curing oven. The last part of the process involves the use of a Necker Flanger, which narrows the opening to form a neck and flange.
A boiler, or also called a steam generator is a device used to create steam by applying heat energy to water. The types of steam boilers we have worked on are on power plants, also called generating stations. These power plants, or generating stations supply electrical power to cities, or in some cases a facility that has their own power plant. The boiler is one of the components of a steam turbine. Steam is only one source of power generation as there are also gas fired and coal fired turbines.
Bottle unscramblers sort or unscramble containers that are housed in some type of supply hopper and organize them to be used along a production line conveyor system where they are filled. They work on a wide range of bottles and containers, including those used in the pharmaceutical, food and beverage, household, chemical and cosmetic industries. This includes items like dairy products, bottled water, juice, car care products, detergents, cleaners, lotions, motor oil, hair care products and many more—all of which often offer the same product but in different size bottles. Some companies will use a Depalletizer or an Uncaser to load bottles onto the conveyor, and others use Unscramblers.
Drop Packer-Case Erector-Cartoner – a case packer is used to put, or drop (Drop Packer) product into a box or tray. Some packers are all-in-one units that are also a Case Erector or Cartoner, where they take the broken down box or tray and form the sides to make it rigid. Some of them will have taping systems, and some will have glue systems. Many of them are very efficient, packaging multiple cases simultaneously. The brands we have installed are Thiele, Douglas, Hartness, Hamrick, Combi, and Standard Knapp. However, we can install or overhaul any brand.
Converting equipment is used in the paper, foil, textile, and plastic film industries. In the process, the media used (foil, paper, film, cloth, etc) is placed on a continuous roll, known as a web. The web is placed on an Unwinder or sometimes called a back-stand, and then the web is threaded through the processing machinery (Printing Presses, Laminators, Coating and Slitting) and converts the web into an intermediate or final product. This is referred to as web processing. Other equipment used in converting processes are Die Cutters, Rewinders, Embosser, Sheeter, and Baler (also written as Bailer).
Fillers are used in manufacturing for filling liquids, gels, or other viscous materials into a bottle, can, or a container such as a pouch. There are also dry mix fillers (flour, sugar, etc) that use an auger or agitator. Fillers come in a variety of types, but we are most familiar with the in-line and rotary (filling valve) types. Rotary fillers are the fastest and can bottle anywhere from 20 bottles a minute to over 1000 bottles a minute. Liquid fillers are typically installed with a Capper or a Crowner downstream from them. A capper installs a cap on top of a bottle, whereas a crowner/seamer will install a top on a can. The machine speeds of a capper or crowner are synchronized with that of the filler. The fillers we have installed have been used in the food and beverage (beer, water, wine, juice, soup, liquor, soft drinks), medical (liquid medicine, inhalers, natural remedies like aloe vera, etc), cosmetics (shampoo, creams, lotions) and the pharmaceutical (eye drops) manufacturing industries. Although we can install any manufacturers equipment the brands we are most familiar with are Krones, Fogg, Simonazzi, KHS, Torr, and Accutek, Comac, and Cleveland.
A palletizer and a depalletizer are relatively the same piece of equipment, but they work backwards from the other. A palletizer is on most occasions the last piece of equipment in the production line process. Sometimes, there is an additional piece of equipment, called a Stretchwrapper, that straddles pallet conveyors downstream from the discharge of a palletizer. A palletizer is a machine that provides automatic means of stacking cases of goods or products onto a pallet with multiple levels. The infeed can be controlled with conveyors that divert the product into lanes with continuous motion flow, or with a robotic arm. A depalletizer works just the opposite of a palletizer, because it unloads product containers that have been palletized onto a mass conveyor. An example of this is when a manufacturer bottles or cans a product. They are in the manufacturing business for their product, not to manufacture the cans or bottles. Therefore, semi-trailers bring the palletized bottles/cans to the manufacturer's facility and they are loaded onto pallet conveyors which feed the depalletizer. A depalletizer will unload one level at a time until the palletized unit is completely unloaded, and then will start the sequence over again for the next one. Alvey, Busse, ABC, Columbia, and ABB Automation are all manufacturers we have installed on past projects.
A pasteurizer is a controlled heating chamber designed to kill disease-causing organisms such as bacteria. Milk is one of the most widely pasteurized foods, but pasteurizers can also be used with a variety of other foods or beverages such as dairy products, low alcoholic content beverages like malt beverages or beer, wines, juices, canned foods, water, syrups and vinegar. Pasteurization is used to make food safer, so that it can be sold commercially without concerns that people will get sick when they consume it. Unlike sterilization, pasteurization is not intended to kill all micro-organisms in the food. Instead, it aims to reduce the number of viable pathogens so they are unlikely to cause disease (assuming the pasteurized product is stored as indicated and is consumed before its expiration date). Pasteurizers can work in a number of different ways. One of the most common styles is the high temperature, short time (HTST) or flash pasteurizer, which brings food to a very high temperature for a brief period to kill bacteria before rapidly cooling it. Related is the higher heat, shorter time (HHST) pasteurization method. Pasteurizers can also be used for ultra heat treatment pasteurization, high pressure pasteurization, and extended shelf life pasteurization, which can render foods so stable that they can be stored at room temperature in aseptic containers for several months. The majority of pasteurizers our company has installed are the tunnel type, with most of the installations going in the breweries. Sander Hansen and Barry Wehmiller are both brands in which we have the most experience. We have also converted some of the older walking-beam type pasteurizers to mat-top. Get in touch with us if you need some assistance in doing so at your facility.
Rinsers are used in a variety of ways, but the most significant use is in a filling line (bottled water, beer, sodas, salad dressing, or other edible or drinkable products). When used in a filling line, they are placed just prior to the filler to rinse the container prior to being filled. The two types used are wet and dry rinsers. Wet rinsers use water and possibly another media. There will be a twist at the infeed end of the rinser to invert the bottle where jets can shoot into the container to remove dust and debris. Upon exiting the rinser, the container will go through another spiral to turn it right side up. A dry rinser will use air to remove the dust and debris, and some have vacuum systems. A Gripper Rinser is one of the most common dry rinsers used.
Weighers come in a variety of types for a variety of industries. Batch weighers (also called load cells) can be mounted above or below product to get an accurate measurement of weight or volume. This is only one use of a load cell, because we have installed them in the automotive assembly plants, bottling plants, soup manufacturing facilities, and other plants. A Multihead Weigher is much more complex and is a piece of equipment that not only weighs multiple quantities simultaneously in various hoppers, but it calculates out which ones to drop together to get the desired weight. The processing capability of a Multihead Weigher is equivalent to over 50 workers. Multihead Weighers are mostly used in the food and snack industries for potato chips, pretzels, nuts, popcorn, crackers, salad, candy, etc. But, they are also used in other industries producing metal components or plastic goods. We have installed numerous weigher/scale-metal detector-bagmaker combinations.