Multi-Conveyor  recently provided a multiple lane table-top conveyor system incorporating a 4 to 1 merge for cartons. Although the packaged snack food manufacturer originally requested three 2:1 combiners, Multi-Conveyor offered an economical 4 to 1 solution which saved the client both floor space and money. The system incorporates four lanes of pneumatically actuated clamping devices and blade stops that are used to control the traffic of four rows of product and merge them seamlessly down to one lane for delivery to a palletizing system. The clamps and blade stops operate automatically by sensing product back-up in each lane while in production mode, or, they can be closed prior to product arrival when a predetermined stoppage in the line is necessary. Electronic sensors are used to determine back-up conditions, detect product presence at the devices, notify when devices are clear for actuation. The sensor feedback dictates sequenced product release and line conditions.

The entire solution integrated table-top and modular plastic belt conveyors, five single  lane incline and two double-lane decline spiral conveyors and high friction decline belt conveyors. This arrangement gave the customer overhead conveyance to allow access to floor level machinery. The solution also included a 4-lane vertical divert to deliver cartons to either of two case packers or to the 4:1 Combiner. The mechanical design and electrical system controls engineered by Multi-Conveyor and entirely built at their facility utilizing an elaborate on-site UL panel laboratory, complete fabrication area and assembly. The system was then set up and wired for a Factory Acceptance Test (FAT) by the customer. The overall system included over 930 feet of conveyor of which 550 feet also incorporated pneumatically adjustable stainless steel guide rails for control of the six different carton sizes.