Essity Saves €400,000 in Production Costs by Switching to Intralox DARB Sorter

Customer Objectives

Essity, a leading Spanish diaper bundles manufacturer, was facing frequent jams and unplanned downtime due to their existing ball belt reject system. Its inability to handle various product sizes caused three jams a week on four lines—12 jams total. Each jam took 20 minutes to clear, creating annual losses of approximately 192 hours in downtime and 71,200 packages. Plus, Essity wanted to integrate a vision system to monitor product quality, but the ball belt reject system didn’t provide sufficient controls for this.

Intralox Execution

In 2014, Essity installed our Dual-Stacked Angled Roller Belt (DARB) Sorter S4500 and it’s always run smoothly. Due to this success, they partnered with us again for reliable service, straightforward installation, and easy maintenance.

Essity replaced all four ball belt reject systems with reject systems using our DARB Sorter S4500. This reliable, single-unit solution delivers high-performing automated reject sorting for a wide range of product types.

Results

The DARB Sorter S4500 immediately improved Essity’s production lines, achieving and exceeding all their goals. It handles all of their product sizes, eliminating €400,000 in costs resulting from jams, wasted and reprocessed product, and unplanned downtime. The sorter’s precise controls support their desired vision machine, allowing Essity to ensure product quality.

Essity was highly satisfied with Intralox’s services, as well as the easy installation and reliable equipment. We provided clear points of contact, ensuring Essity always knows who to ask for help. They plan to work with us on any future equipment needs.