A confectionary customer needed to package chocolate products shaped like potato chips. These products were produced using a non-conventional proprietary process that produced an output of 16 individual lanes of product not aligned in rows. These products were required to be packed in thermoformed plastic cups, oval in shape, with the products nested in a stack. Graybill configured a reverse feed packaging line with cup droppers that dropped 16 individual cups into independently indexing flight chains, all operated on demand of the incoming product. Product stacking at over 2000 pieces per minute was done using 32 linear servos. In addition to space constraints and difficult to align containers, Graybill solved problems with product alignment and bounce at the drop point. Three of these lines were built.
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