Intralox and SEE Sistemas Achieve 95% OEE and 33% Increased Throughput for Shampoo Manufacturer

Customer Objectives

A shampoo manufacturer was looking to increase their throughput rate from 30 packages per minute (ppm) to 45 ppm in a compact footprint while enabling gentle product handling to minimize or eliminate packaging damage. In addition, they wanted to prepare for the future by investing in technology that would handle future pack sizes.

Traditionally, the technology used to achieve this would include five dual-lane pneumatic pushers feeding a robotic palletizer. This traditional approach would not achieve the desired throughput goal and would damage the product packaging while adding more complexity and controls to the line.

Intralox Execution

The shampoo manufacturer contacted their OEM, SEE Sistemas, to determine the best possible solution to achieve their goals. SEE Sistemas partnered with Intralox packaging and layout optimization experts to reach their overall equipment effectiveness (OEE) obligation to the manufacturer and minimize line complexity.

The Intralox solution included a five-station Dual-Stacked Angled Roller Belt (DARB) Sorter S4500 leading to S1000 Flat Top belting for efficient accumulation and tight transfer of small products. Intralox also provided a S2400 Radius Flush Grid belt to accommodate the existing footprint, and S900 belting for pallet pattern forming. SEE Sistemas and Intralox layout optimization experts worked together to ensure the installation process was efficient with quick and easy startup. Intralox tested all products before the sale to ensure SEE Sistemas would reach their OEE obligation of 95%.

Results

Due to the DARB Sorter S4500 arriving assembled, SEE Sistemas saved 50 man-hours without needing to assemble and install the five pneumatic pushers. With efficient sorting and accumulation, gentle transfers, and pallet pattern forming in the existing footprint, the solution is far less complex. Product damage due to pushers has been eliminated and operations are future-proofed for different pack sizes.

The shampoo manufacturer has experienced reduced controls on their line and a 33% increase in their throughput since installation. SEE Sistemas saved time on installation and achieved their OEE obligation of 95%.