How To Minimize Product Tipping Or Spilling On Accumulation Tables

Can the advanced accumulation systems manage a large number of products?

Yes, they can, provided the products are stable, and there is no spillage. Otherwise, a business can face the following consequences.

• Production Delays
• Wasted Materials
• Costly Cleanup

So, the question is how you can ensure product stability on accumulation tables?

• Well, maintaining proper line pressure, between 2-3 PSI, is still the most efficient way.
• You also have to ensure that the container height-to-width ratios are not more than 2.5:1.
• Again, the conveyor speed needs to be under 100 feet per minute.

Now, these are the basic parameters, and you need to follow them for a good starting point. However, there is more to ensure product stability on accumulation tables.

Two other major factors involved are container design and the material of the table surface. Understanding these and all the other factors and eliminating them are essential to get rid of chronic spillage problems.

Here is more to achieving smooth and efficient operations.

What Are The Factors That Affect Product Stability On Accumulation Tables?

There are three aspects that you want to know about the factors impacting product stability on accumulation tables.

1. The Characteristics Of The Products

The products have some inherent physical properties that affect the product stability on accumulation tables.

● Size, Shape, And Weight Of The Product

Are you handling small wine bottles or vials? These are narrow products and thus have a higher center of gravity. So, these are less stable and very prone to tipping.

On the contrary, when a product has a wider base with a low center of mass, it will remain stable on the accumulation table.

● Surface Finish

The surface finish of a product impacts the amount of friction with the conveyor surface. If the surface is very smooth, for example, glass, the friction will be very low.

Thus, the movement of the products on the accumulation table will be unstable, and this can lead to damage.

● Durability

Gentle handling is important when a product has a “fragile” label. You have to choose the zero-pressure accumulation method to avoid pressure and contact.

Thus, you can avoid spillage.

● Packaging Material

Similarly, the packaging material of a product decides how much pressure it can endure on the accumulation table.

If the packaging material is fragile, there should be minimal to zero pressure exertion.

2. Accumulation System Design

The accumulation method, the material of the conveyor belt surface, lane management, and guide rails are the factors related to the accumulation system design.

3. Operational Conditions

Operational conditions refer to the line speed, environmental condition factors, and the accumulation rate or density.

For example, if the line speed is high, there will be instability. Also, if the accumulation density is higher, a product can fall over.

Accumulation density is all the more crucial when you are managing products with mixed sizes.

In addition, temperature and humidity are the environmental factors that impact the stability of the products on accumulation tables.

Environmental factors are more crucial when managing pharmaceutical and food products. These have a serious impact on product safety for consumers.

How Does Container Loading Pattern Impact Stability?

The way products queue and accumulate on the table can significantly affect their stability in production queue systems.

A staggered or offset pattern often provides better stability than products lined up in straight rows. This is because each container helps support those around it, creating a more stable group formation.

Proper guide rail adjustment is essential when establishing accumulation patterns. Rails should be set to allow smooth product flow while preventing excessive side pressure that could lead to container deformation or tipping.

What Role Does Product Weight Distribution Play?

The distribution of weight within containers can make a substantial difference in stability during accumulation. Top-heavy products are more prone to tipping, while those with lower centers of gravity tend to remain upright more consistently.

For products with uneven weight distribution, consider using specialized accumulation table surfaces or adjusting accumulation patterns to compensate. In some cases, modifications to packaging design might be necessary to achieve optimal stability during the accumulation process.

This is particularly important when dealing with partially filled containers or products with varying fill levels, as these can create unpredictable behavior during accumulation.

What Speed And Pressure Adjustments Can Optimize Accumulation Stability?

Fine-tuning conveyor speeds and line pressure is often an overlooked aspect of preventing product tipping.

The key is to maintain consistent speed transitions between the main conveyor and the accumulation table. Sudden speed changes can create shock waves through accumulated products, leading to instability.

Line pressure should be monitored and adjusted based on product characteristics and accumulation patterns.

Too much pressure can cause products to compress against each other, potentially leading to deformation or tipping. Too little pressure may result in gaps that allow products to fall over.

Regular monitoring and adjustment of these parameters, especially during product changeovers, can significantly improve stability and reduce spillage incidents.

Taking Action On Your Production Line For Product Stability On Accumulation Tables

• Conduct a comprehensive audit.
• Ensure the accumulation table settings are according to the products to be handled.
• Focus on line pressure and conveyor speeds.

These are the baseline assessments that you need to document. Then, you have to make small adjustments.

Here, remember that you cannot fix all things at the same time. There will be too many variable factors. Fix one problem, monitor the result, and then move on to the next for optimal configuration.

Done with the settings? It’s time to create a detailed SOP or standard operating procedure. Thus, there will be consistency across all operators and shifts.

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