Fastener distributors continually face the issue of packag- ing hardware fast and accurately. Distributors such as ARC Fastener Supply, Inc. in Azusa, California need speed and accuracy, but because of the variety of parts being packaged, they also require packaging equipment that is versatile.
ARC Fastener's customer base is primarily original equip- ment manufacturers (OEM) who demand service and value pricing. With the advent of quality management systems like ISO 9000, OEM's are also demanding perfect products and holding the suppliers responsible.
Searching for the Right Solution
Joseph Myers, President of ARC, started looking for equip ment that would offer speed, accuracy and dependability, He purchased some different brands and found that speed and accuracy were difficult things to attain together. As most equip- ment increased in speed, its accuracy rate decreased. When the equipment was slowed down to improve its accuracy, it still needed to be checkweighed to ensure correctness.
Another problem that appeared was the weight range of the bolt kit being packaged. The average weight of a kit would range from a few ounces to 8 lb (3.6 kg). "The conventional roll baggers just could not handle the constant pounding of hard- ware placed on them. The roll baggers were being beat to death by hardware," said Myers.
The differing levels of support offered by those companies and the fact that most did not offer a complete turnkey system made maintenance and repairs difficult.
By the time Myers learned about Batching Systems, he had almost resigned himself to the fact that hand assembling bolt kits would be the most consistent method. He was looking for a system that would be versatile enough to handle the variety of parts, reliable enough to handle the large volume he pro-
cesses and accurate enough to meet the demanding require- ments of his customers. The company also had to stand be- hind its machines and offer a comprehensive warranty.
The Fast Automatic Weigher and Kit Packaging System
ARC purchased a Batchmaster® Fast Automatic Weigher (FAW) as a test of the speed and accuracy claims. Myers said, "Production began immediately with outstanding results." The weigher produced an average of 15 to 18 units a minute count- ing hundred packs of screws and nuts. Other hardware items also had the same results. ARC's QA Manager's accuracy report read, "The counter would only over count one piece and that occurred very seldom maybe one out of a thou- sand units run."
ARC then purchased a complete Batching Systems Kit Pack- aging System (see Figure 1) consisting of 11 Batchmaster Counters, three Batchmaster Fast Automatic Weighers (FAW), a collating bucket conveyor, box conveyor, take-away con- veyor and a Bagmaster® Series C vertical form, fill and seal machine with a printer. While ARC is presently using 11 counters and three weighers, the system is expandable to handle 22 filling stations.
ARC currently runs 14 to 16 tons of hardware a day on the Packaging Line. Production is nine times greater than before the purchase.
Counting and Feeding
The counters (see Figure 2 and Figure 3) feature patented Dual View Optics which view parts from two different angles and enable ARC to measure the volume of parts as they pass through the optic eye. If the part is smaller than the set param- eters, it is not counted or if the part is nested with another, it will identify it as two pieces. This is one of the most accurate means of counting on the market, ARC has an assortment of 60 mm (2.4") and 100 mm (3.9") optics enabling the company to count parts as small as 1/32" (0,8 mm) ball bearings and as large as 5" (127 mm) long bolts. Another benefit of the optics system is its ability to count shiny and/or very thin parts.
The singulation of product is an extremely important factor for counting hardware. Batching Systems has accomplished this with its Enhanced Geometry Bowls (see Figure 3) that are capable of tracking parts at 600 linear inches per minute (15.2 mpm). The operator can electronically adjust the vibra- tion of the bowl to the weight of the product. An outside track bowl for difficult shaped parts such as allen keys and lockwashers can also be provided.
Computer Controls
Myers refers to this packaging system as "the smart sys- tem with electronic intelligence." The bucket conveyor, counters and bagger receive their demand signals from an Allen Bradley Pro Logic Controller. It allows the conveyor to signal the counters to dump into a numerically assigned bucket. When the last bolt kit is being produced, the counters are signaled to stop dumping. The conveyor will continue carry- ing product to the bagger until all of the assembled bolt kits have been bagged. This leaves the conveyor empty and ready for set up for the next bolt kit.
Other conveyor systems count the product at the bagger and leave the conveyor full of product. This results in either overruns or longer changeover times to clean out the buckets.
On the rare occasion that a counter miscounts a part, a signal is sent to the controller, and the bucket is electronically tagged. When the kit reaches the bagger, the hagger bags the miscounted kit and sends it down a rejection chute not allow- ing it to come in contact with the good product.
Off-line computer software increases the storage capacity to the limit of the computer and enables the operator to store and retrieve kit setups as well as plan additional kits while the system is in operation. The operator can select a kit and the computer will set the parameters for the hardware at each count- ing/weighing station, identify the part to go into each station and program the bag size. This allows physical changeovers to be done in minutes without tools. Each Counter or FAW can typically changeover from one part to another in less than three minutes.
Bag Specifics
Fig. 6 Operator inspects the final product at the computer station.
The Bagmaster Series C Bagger (see Figure 4) uses centerfold film and can make bag as small as 2.5" x 2.5" (63.5mmx63.5mm) and as large as 9"x11.5" (229 mm x 292 mm) that holds up to 8 lb (3.6 kg) of product. Bagmaster Vertical Form, Fill, and Seal machines generally offer material cost sav- ings over roll baggers using preformed bags. Myers estimates a savings of 80% on materials. "We're saving US$5,000- US$6,000 per month on poly," he said.
Some of the added features of this bagger are that it can produce cellular bags that separate delicate and/or high finish parts from other parts in a kit. It produces a package with several sealed separating pockets in one package. The design of the infeed to the bagger captures large, small or difficult products and virtually eliminates product spillage in the bay filling process. A sample package is shown in Figure 5.
The most unique feature of this machine is its ability to produce a bag that is free of a back seal. This makes it ideal for printing on the front and back resulting in a very professional looking package.
As with all Bagmaster Baggers, the C Series has a PLC control and bag lengths can be changed instantly. The bag width can easily be changed by replacing the centerfold sup- ply roll with a different sized roll. While ARC predominantly uses poly film, the machine can use laminated and cello film as well. According to Myers, "Batching Systems' equipment has become our packaging solution."
