Single Source OEE Optimized Turnkey Conveyor Lines

Statera has extensive experience in a wide variety of packaged goods industries, including ready-to-drink beverages, bottled waters, foods, automotive fluids, personal care products and home care products. Once products are securely in their primary packages, Statera conveys them so they can be aggregated and placed into secondary packaging, including corrugated boxes, cartons, trays, trays with shrink, bags, shrink bundles or crates. Filled secondary packages are then aggregated on pallets, stretch-wrapped and conveyed into the warehouse, from where they ultimately find their way into a truck, rail car or shipping container. For rigid or flexible primary packages, secondary packaging or palletized products, Statera can design, manufacture, integrate and install a conveyor system, including all three for an end-to-end conveying solution.

Preventing problems is far less costly than fixing them. Validated, experience-based conveyor and packaging line design tools set Statera apart from other companies offering conveyor and line design, integration and controls programming services. These tools guarantee that Statera turnkey solutions do not experience the inefficiencies and downtime that other vendors unintentionally design into their conveyor systems. OEE-optimized conveyor and packaging line design is a science, not an art, and Statera’s proprietary formula-based tools deliver accurate, consistent and on-target results. The tools precisely calculate proper machine placement, proper quantities and types of conveyor transfers between machine centers, optimum machine speeds, optimum infeed and discharge conveyor speeds, and optimum accumulation capacities. They replace the guesswork, the opinions and the conventional wisdom used by other suppliers with validated formula-based tools that convert production line requirement inputs into practical design criteria. Experience has taught Statera and its repeat customers that numbers, when used correctly, never lie.

Expert line control system design and programming is essential: conveyor line control system design and programming are one of many keys to achieving optimized packaging line performance. Statera’s line controls experts and programmers have extensive experience in a wide range of industries and product types, and its line design engineers and controls programming teams work hand-in-hand through every phase of a project to deliver high-performance integrated conveyor systems. The goal is always the same: consistent, dependable, steady-state production. Extensive industry experience with a wide range of challenging projects has taught Statera that optimized line performance can be guaranteed by coordinated design teams keeping line layout and line programming considerations top-of-mind throughout the project. Dozens of factors must be evaluated during this process: primary and secondary package types, shapes, sizes and rigidity, as well as target production and surge speeds, must all be part of the design process because of their impact on machine speeds, machine placement and required accumulation technologies. Other vendors commonly design a line and then task their controls teams to work out the bugs with programming and controls, an expensive and painful process for customers; designing a line and then figuring out how to make it run efficiently through programming is just a bad idea. The Statera approach focuses on delivering optimized total line performance through line control programming that integrates and synchronizes conveyor controls, conveyor speeds and individual machine controls. Designing conveyor control systems and programming the entire conveyor system to work seamlessly with the machines in the line is as essential to line performance as the machines themselves.