Over/Under Box Filling System
Available in Powder Coated Welded Steel or Extruded Aluminum

Automatically fills empty boxes on lower level and lifts full boxes to upper level while using very little floor space. This eliminates the need for bending down to take away full boxes and allows molding machines to be unattended for longer periods. The box filling process occurs on the lift platform using cycle count, part weight or visual count. In addition, rejects, startup shots or quality control samples can be diverted within feed chutes or conveyors prior to the box filling to fully automate the molding process.

System Features

• Fill by Net weight, weight count or cycle count
• Available in 2, 3 or 4 levels to maximize floor space utilization
• Combine with our other equipment to create a custom system
• 5 Year Limited Warranty

System Benefits

• Parts count per tote or box already weighed or counted (Operator does not need to count or weigh parts)
• Less boxes and totes overfilled and parts getting onto the ground turning into scrap
• Can be used with various size boxes for future customer packaging de-mand changes
• Operator only needs to focus on un-loading the full boxes and sealing it for shipment (A single operator can handle many more production lines)
• No more bending over to pick up full boxes and totes

Increase Capacity and Flexibility

A MAC-Stack system provides the most efficient use of space both in the linear direction as well as in usable width di-mension. The system size determined by the size and number of containers re-quired for a certain amount of unattend-ed run times. Systems for cycle count controls consist of an indexing conveyor, a gravity type accumulation conveyor, an equipment sub-frame, a pneumatic or electric belt elevator type of lift, a control panel and leg supports with an end stop at the end of the gravity conveyor.

Systems having weight scale controls also include a powered roller style weigh scale conveyor with a single point load cell with weigh scale controls, which can be positioned either before the elevator or on the elevator, depending on the space requirements. The orientation of the conveyor is normally belt conveyor on bottom and gravity on top, but may be reversed depending upon the applica-tion. These systems are usually posi-tioned along either side or the end of the press with an under the press or multiple under the press conveyors feeding the container indexing and loading system.

Operation Sequence
Empty totes/boxes are loaded onto the lower level belt conveyor. The belt con-veyor indexes the tote/boxes as required onto an elevator lift platform where con-tainers are positioned to receive parts as they are delivered from a feed conveyor. First, the containers position is confirmed by photo-eyes, which are regulated by the system’s PLC (Programmable Logic Controller). Once confirmation is re-ceived, a signal is given to start the feed conveyor to deliver parts to the box. When the container has approached a preset target count, the feed mechanism is signaled to slow down to a “trickle feed” to hit the final fill count. This se-cond signal stops the feed conveyor when the final fill count is reached. Either the platform will lift the full container to a gravity style roller conveyor or the ver-tical transport platform may lift and then drive the full container onto the roller conveyor. This function is dependent upon the fill point location. Full contain-ers accumulate on the roller conveyor. Photo-eyes monitor box positions and may activate optional audible and visual alarms, when the system requires atten-tion. Alarm conditions include: No empty containers in queue; no containers on lift or in fill position; indexing sequence ex-ceeds time limit indicating either an air pressure problem or container jam; and the accumulating gravity roller conveyor may be full.

Reduce Production and Labor Costs
A quick return on investment (ROI) out-weighs the initial setup costs. Typically the payback period for a MAC-Stack is less than a year. By utilizing an automat-ed filling system individual workers be-come more efficient allowing plant man-agers to eliminate extra labor costs. Stop having operators bulk pack your parts. Fill boxes or totes by weight or shot count. Cut down on labor, liability, cost and automate to run 24/7/365 days a year! We can custom design a system to satisfy your particular needs. System implementation dramatically improves accuracy and enhances product quality.

MAC Automation manufactures many other box filling systems.