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More than 800 projects completed throughout North America, Europe, and Asia"

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Case Studies


Business: Caulking Manufacturer - Automated Facility

Nature of Work or Scope and Results

This study of two sites for location of a proposed plastic extrusion and cartridge loading operation involved providing layouts and site plan analyses as well as projected capital investment costs and operating expenses for each site. The facility was designed for optimum automation, with a finished goods inventory capacity limited to the surge capability necessary to permit five-day shipping and seven day production. To minimize scrap loss and clean-up costs, consideration of introducing color immediately before the Geyer filling operation was considered, but rejected as technically impractical at the time of the study. Other design considerations included plans to centralize packaging and distribution of small packaged items normally marketed in non-bulk form, the intended conversion from a foil lined paper cartridge to a plastic cartridge, and the length of feed lines to the Geyer filling operation.

The final design included two six-line Geyers for each compounder/extruder to provide maximum color change flexibility and ensure line surge capacity. Differences in the two locations involved only the length of conveyor belts and piping necessary for operation. Both designs included a multiple overhead accumulation conveyor system to buffer manufacturing output rates, automated handling of product and semi-automated handling of packaging materials, the use of a combination of pneumatic, feed hopper, continuous flow unloading of raw materials, and the use unscramblers, case packers, pallet loaders, and shrink wrapping machines in the packaging area. The storage system used a FIFO flow-through pallet rack with gravity conveyor and braking rollers, serviced by a "Cartrac" system capable of pushbutton delivery of loaded pallets to storage slots and roll-through racks.


















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