Baking & Snack - October 2009 - 82

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points where there was no space for
other cases to be pushed into. Consequently, merge points further down
the line were unable to push the cases out into the packing hall.
Corners were another problem
area in the previous packing hall
layout. The cases could not be manipulated, so the spacing required
for the cases to negotiate turns
comfortably was not possible. As a
result, the cases would be crushed,
and a jam would quickly result.
The result of these frequent jams
was a steady production loss that
made it difficult for the facility to
meet demand.
PepsiCo evaluated several options for a new packing hall layout
that would deliver greater efficiency. Although PepsiCo had not previously worked with Intralox, its
officials had seen videos of the new
Activated Roller Belt (ARB) technology for the back end of the plant
and were able to see that the Perpetual Merge solution in particular
could solve the facility's problem of
jams at merge points.
Intralox helped redesign the
packing hall of the plant, along
with an ARB-licensed original
equipment manufacturer who was
awarded the project. Using modular
plastic belting and ARB technology
in merging, switching and sorting
applications, Intralox comprehensively upgraded the plant's packing
operations. "We installed Intralox
belting as part of a complete rethink
of our packaging hall conveying
operations," said David Randell,
technical manager, PepsiCo.
Since the upgrade, the facility
has exceeded its goal of 65 cases
per minute. In fact, the Intralox
technology allowed it to increase
packing capacity from 52 to 82
cases per minute. Cases can now
be packed on the belt, so the labor
previously required to walk cases to
case sealers is no longer needed. As
a result, the plant has experienced
an 18% improvement in packing

efficiency and has been able to significantly reduce labor costs.
The plant now benefits from fewer
jammed cases per shift, and in most
instances, zero jams are reported.
Because the Perpetual Merge solution employs continuous motion,
no stop-starts are necessary, and
thus accumulation is used only to
keep the system clean. Plant personnel have just enough accumulation
to clear the different applications
so that the system can be restarted
without any recovery time. In this
sense, the Perpetual Merge has made
the operation a more instantaneous
system. If a jam does occur, it takes
much less time to clear. As an additional benefit, the packing hall upgrade will help the plant meet packing capacity needs for the next five
years. "Not only has our conveyor
handling capacity increased, but it is
now more flexible," Mr. Randall said.
"Unique and simple solutions such
as the Perpetual Merge allowed us to
create a continuously flowing system
with few stops and starts, achieving
high throughput with fewer jams
and no bottlenecks. Belts are easy
to keep clean, and the issue of tape
wrapping around rollers has been
eliminated. While it is still in the
early stages, it is proving to be a reliable system and is likely to become
the benchmark for future PepsiCo
carton conveying installations."
PepsiCo's site project engineer
Andrew Davies agreed, "Since
the upgrade, the Adelaide plant is
considered to be PepsiCo's model
plant and other plants are looking
to learn from it in order to improve
their conveyor systems and enhance efficiency."
Finally, the upgrade provided increased worker safety and reduced
occupational health and safety costs.
The system was designed to meet
Australian safety requirements, and
the plant reports that operator safety
greatly increased, particularly in
manual handling, where work-related
injuries have been reduced.
◾

Fifty Years of
Good Taste

Jill

ethel Bakery, known as The Cake
Place, celebrated its golden
anniversary in September, 2005.
Located in Bethel Park, Pennsylvania,
the bakery staged a week-long celebration that enjoyed great community
support. "We doubled our normal
customer count each day;" said John
Walsh, Bethel Bakery President.
"Bethel Bakery is beloved in our
community."
There was no doubt about where to
turn for an anniversary cake. Nearly
80 percent of Bethel Bakery's business
comes from cakes, including cupcakes,
dessert cakes and wedding cakes.
But Bethel is widely known for its
decorated cakes and signature French
Buttercream icing.
Family is at the heart of Bethel Bakery.
John, is the oldest of seven children
and took over from his parents, Morris
and Anna Walsh, in 1991. Both
Morris and Anna still find time to
visit the bakery. Anna loves serving
customers, and Morris, aside from
being a master baker, is a valuable
jack-of-all-trades. And with a 7,000square-foot facility, there is always
something to be repaired. John's sister,
Christine Makowski, oversees wedding
cake sales, and John's wife, Chris, contributes administratively. John admits
having four kids has kept his life balanced. "Staying involved in my kids
lives helps keep me from becoming
totally consumed by my business."
John believes that keeping quality
consistent, day-to-day and year-to-year
is one of their biggest challenges.
"Bethel Bakery has been an
International® Bakers Services'
customer for decades," he continued.
"We rely on International® flavors to
provide the consistency we require for
our ongoing success."
When you want consistent results,
turn to International® Bakers
Services. Contact us toll-free at (800)
345-7175, by fax at (574) 287-7161,
or in writing at 1902 North Sheridan
Ave., South Bend, Indiana 46628.
We have the flavors your customers
deserve.
For more information, see Page 101

October 2009 / BAKING & SNACK

Baking & Snack - October 2009

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