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Industry: Food & Beverages

Challenge:

The customer had an existing palletizer line with a 6” top of roller pass height and wanted to add a fully automatic stretch wrapper to the end of their line. Most of the powered roller conveyor sections available have a 12” minimum top of roller height. This would require the customer to install an additional elevating conveyor section, to make major modifications to its existing conveyor section or to pit mount some components.

Wulftec's No Fear Solution: Low Profile Conveyor Section

Solution:

A low-pass height clamp, heavy-duty process conveyor section with special programming to eliminate the need for pit mounting. Here are some of the features found on this particular model:

• 13.5 feet in length
• 52” BFR useable width
• 2.5” diameter, 3⁄16” wall rollers on close 3” centers
• All rollers driven with fully enclosed #40 chains
• Zero pinch point guarding
• Sealed maintenance free cast iron housing bearings
• 6” top of roller height
• Dual 1 HP AC motor drive to clear wrap zone
• Special low profile film clamp to prevent pit mounting
• Wulftec renowned heavy-duty trouble-free construction

Challenge:

The customer had a very restricted floor plan with limited space

Solution:

A full-featured WCRT-200 with an index table in the wrap zone with the following features:

• WCRT-200 with index table for processing
• Rigid steel conduits
• Numatics 2002 series valves
• Automatic air dump valve
• 30° curved conveyor
• 2 x conveyor control packages for the customer-supplied conveyors
• Ring gear grease catch pan
• FDA-rated lubricants
• Flange-mounted disconnect switch
• CompactLogix L32E PLC
• Fuse protection on PLC outputs
• PanelView 1000 Plus Color touch screen
• Banner photoeyes
• Special “Prepare to Start” sequence with audible alarm buzzer
• Low load detection with special programming for low loads
• 4 beacon machine status indicator light stack
• Background suppression photoeye for auto height
• Light curtains around process area
• 12”-high steel legs for enclosure

Challenge:

Customer has 3 palletizer lines that need to be redirected to a single over-head wrapper, but the design has to allow forklift operation on all 3 lines.

Solution:

WCRT-175 featuring a shuttle conveyor with flat rectangle track guidance, overhead festooning system and specially-designed safety bumper:

• 1 x 5’ in and 2 x 5’ out conveyors
• 3-position shuttle conveyor
• Wamfler trolley system
• Safety bumper
  

Programmer Shelf with GFCI 120V Outlet and DH + Port

ABB Nema 4X Disconnects for Conveyors & Washdown Motors

Challenge:

In this case, the customer's product was very easy to wrap. The real challenge was meeting the customer's wide range of requirements - such as easy access for maintenance and a machine that could withstand a very harsh operating environment.

Solution:

A highly customized high-speed WCRT-200 featuring a long list of options, including:

• 12” stainless steel legs under enclosure
• Cover for enclosure quick plugs
• Rigid galvanized steel conduits
• ABB Nema 4X disconnects for conveyors
• Electric air dump valve
• Programmer shelf with GFCI 120V outlet and DH+ port
• Fuse blocks with blown fuse indicator
• Washdown motors
• Fluorescent light inside enclosure
• 30 RPM arm speed
• Warning buzzer
• Power surge protection

Challenge:

The two different palletizers were located at a considerable distance from the wrapping location, making this a particularly unique challenge.

Solution:

A WCRT with a highly customized conveyor line featuring a long list of options:

• 8 x 10' chain powered conveyor system
• 2 x chain transfer conveyors
• 4 x 5' powered roller conveyors sections
• Pairing logic (same palletizer)
• Rigid steel conduits
• Air dump valve
• 30 RPM arm speed
• Allen Bradley AC drives with Device Net module

General picture of the WCRT-200. This picture does not necessarily show the options mentioned on the left.

The customer had a long list of electrical requirements and requested many additional functionalities.

Solution:

A highly customized WCRT-200 featuring a long list of options, including:

• Flange mounted power disconnect
• Different Allen Bradley PLCs
• Lockable local disconnects for conveyor drive
• Air pressure switch
• High speed
• 45 FPM conveyor speed
• Rigid galvanized conduits
• Illuminated e-stop
• Steel-it paint
• 30” pass height
• Fluorescent light in control panel
• 30” film carriage

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