Pack Air Inc. Builds its First Automated Stacker and De-stacker for Confectionary Tote Handling

Fully Automated Tote Handling MDR Conveyor Project

Pack Air Inc.’s primary business is conveyor systems. If another manufacturer already builds a specialized piece of equipment that we need on our line, we typically buy it from them rather than reinventing the wheel. But when our customer requires equipment to do something that the standard suppliers don’t do, we will consider building it ourselves.

Such was the case when one of our projects required a Tote Stacker and De-Stacker that would handle up to 22 totes per minute. In meeting our customer's specific needs, we may have also “accidentally” built one of the fastest Tote Stackers on the market. Let’s dive right into how these extensively engineered devices operate.

How the Tote Stacker and De-stacker Operates

Empty totes, are fed into and out of a Stacker/De-stacker with motor-driven roller conveyor (MDR). Totes entering the system are transferred onto a small automated high-friction modular belt conveyor to stop the totes with high accuracy for stacking or de-stacking. The key to achieving the high throughput rate is the Servo Driven Rack and Pinion Drive technology from our successful Vertical Diverter.

Once a tote is positioned inside, it is clamped by a dog device to lift or lower the tote in the Stacker/De-stacker. Secondary dog clamping devices are integrated above to hold the stack of totes while the clamp below performs the function of stacking or de-stacking.

To help guide the totes in the Stacker/De-stacker, vertical guide rails were installed near each corner of the tote. The two guide rails on the Stacker discharge and De-stacker infeed are built with quick acting gates to allow the full stack to discharge or enter the system.

The machine structure also serves as mounting for sheet metal and polycarbonate barrier panels, and a pair of light curtains protect the full stack height openings. Integrated controls and HMIs allow the operator to change the stacking speed or the number of totes to be stacked from 1 to 8 if they choose to do so.

You can watch our YouTube video below to see it in action if you’re more of a visual person.

Pack Air’s Dedication to Innovation

It’s projects like these where we enjoy thinking outside the box on how to make this conveyor or product handling device perform better. Our core value of Innovation drives us to keep on offering better conveying or product handling solutions for manufacturers who need it. If you’re browsing our extensive product line and don’t see equipment that’s right for you, connect with us anyway! Chances are good that we’ll help build you what you need, even if it’s the first time we’ve ever made it.