The customer came to Morrison to discuss their multipack febreeze line. Initially the plant was utilizing 32 people at hand packing stations, running 2, 3, and 4 packs. The operators/assemblers were putting the containers into a cardboard boot, and then sending the containers through a wrapping machine. The packaging process was extremely slow, labor intensive, and didn’t present the containers in an “attractive” package. Morrison offered a solution that replaced all of the assemblers and was capable of running a 2 pack, 3 pack, and 4 pack package (1 flavor, 2 flavor, or 3 flavor skews).
The video on the video menu was taken during testing at Morrison’s plant, which is why there are random colors/flavors visible in the video. The initial 1-2 lane dividing screws separate containers for the different pack requirements. Once in the appropriate lanes, the containers are metered and oriented. If you look at the containers underneath the machine, it is visible that the containers are rotating/spinning. This takes place to lock the handles in a uniform orientation. Once oriented, the timing screws group the containers for the different pack formations. Once the containers are grouped, the overhead pucks/pallets lower and grab hold of the containers. These pucks maintain a tight package and control the containers as they are inverted to be upside down. Once upside down, a sleeve is applied to the package to keep the containers together. By applying the sleeve, Morrison was able to eliminate the cardboard boot. This not only saved the customer a lot of money, creating a more attractive package because graphics could be placed directly on the sleeve.