Vertical Conveyor System Optimizes Ice Cream End-of-Line Packaging

Froneri, a joint venture between R&R Ice Cream and Nestlé, operates a production facility in Ferentino, Italy, dedicated to manufacturing ice cream for international markets and proprietary brands. The site requires an automated transport solution to move individual frozen products from quality control stations, including metal detectors and scales, to final shrink-packing and palletizing areas. The logistics flow must handle varying formats and maintain continuous operation despite potential downstream interruptions in the packaging process.

Technical challenges in secondary packaging
The primary operational challenge involves managing the transition between primary packaging and palletization within a constrained factory layout. The system must overcome significant height differences to allow for vehicle and personnel movement on the floor. Furthermore, any mechanical failure or planned stoppage in the shrink-packing equipment requires a buffering mechanism to prevent upstream congestion. Because the conveyor chain continues to move beneath stationary products during accumulation, the system must minimize friction to avoid damaging product labels and imprints.

Implementation of modular chain conveyor technology
To address these requirements, the facility integrated the VarioFlow plus chain conveyor system. This modular system incorporates floor-level conveyors and ceiling-mounted sections positioned 2.4 meters above the floor. To bridge the vertical gap between these levels, the configuration includes two-lane spiral conveyors. This dual-lane design provides two independent transport lines within a single footprint, doubling the transport capacity compared to single-lane units of equivalent size. The chain components are engineered for low wear and low friction, specifically to support product accumulation without compromising packaging integrity.

Operational results and buffering capacity
The technical integration of spiral conveyors serves as a functional buffer during machine downtime. When the shrink-packing machine stops, the transport speed of the spiral conveyor is reduced, allowing products to accumulate. The system provides enough storage capacity to hold approximately one-third of the total product volume in the infeed, enabling a buffer period of one to three minutes. This window allows operators to address minor technical issues without halting the entire production line. Additionally, the elevated conveyor placement optimizes the facility floor space, facilitating the movement of pallet transport vehicles beneath the production lines.

Edited by an industrial journalist, Lekshman Ramdas, with AI assistance.

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