Wrabacon Helps Its Client Overcome Its Labor Shortage Challenge with an Innovative Idea

The Challenge

The numerous health benefits of fresh fruit are no secret. Low in calories and high in essential vitamins and minerals, fruits are a no-brainer as a snack or an additive to your favorite meals. The challenge, however, becomes keeping up with the high demand for these nutritious treats. To transport product in such bulk quantities, companies often turn to specially designed trays or boxes to help carry the load.

A company approached Wrabacon with an issue. Due to a labor shortage, the company was not able to hand stack and case pack their trays fast enough to meet demand. Wrabacon was up to the challenge, with an efficient, reliable solution.

The Wrabacon Solution

To fix this, Wrabacon custom designed and manufactured a 5-lane tray stacker to be used to receive trays from an existing dryer. The trays are 16.5” long x 12.5” wide and are produced at the rate of 25 per minute.

The trays exit an existing cold belt and transfer onto an accumulation belt and then onto the stacker infeed belt. The trays enter the accumulation conveyor which pulls a gap between trays. They then transfer to the stacker infeed belt which delivers the trays to each individual stacking module. Each stacker works independently from one another and stacks product on demand.

As the stacker continues to stack product, a top cylinder is continuously holding the stack in position. When the desired amount of product has been stacked, the plate/lift cylinder stays in the up position while air is applied to the top cylinder, pressing the stack. After pressing, the stack is pushed out of the stacker onto a conveyor. Once all 5 lanes have produced a stack of the desired quantity, the conveyor moves the product to a table for manual removal.

How Can Wrabacon Help You?

Wrabacon prides itself on developing innovative solutions to your challenges. Contact us today and let’s talk about your situation.

Watch the Video of Our Solution at Work

 

 

 

 

 

 

Covid-19 Response

Wrabacon, Inc.
150 Old Waterville Rd
Oakland, ME 04963
P: (207) 465-2068
F: (207) 465-2134

April 17, 2020

To All Our Valued Customers,

Wrabacon Inc. will continue to remain open during this COVID-19 virus outbreak.

We are adhering to the precautions recommended by the CDC for safe distancing as well as personal and workspace hygiene protocols to keep our employees and their families safe. We also review CDC updates daily and implement new measures as needed.

Everyone at Wrabacon wishes good health and safety to all through this difficult time.

If you have any questions or concerns, please don’t hesitate to reach out to us at [email protected] or call 207-465-2068.

Robert Bartlett
President

Candy Bar Inspection System for Proper Label

The Challenge

Candy bars are a timeless staple of American family life. It doesn’t matter if you prefer crispy toffee centers, crunchy almonds, or warm caramel: these sugary snacks bring families together, whether it’s a grandparent sharing an old favorite with their grandkids, a nice treat at a company meeting, or a tasty Halloween surprise.

Candy bar production, though, can be a far thornier process. Candy manufacturers must vigilantly ensure that each type of bar is wrapped accurately, every time. Mistakes are not acceptable — not simply because of people’s differing tastes, but because food allergies to common candy bar ingredients, such as peanuts, mean that the slightest errors can result in deadly consequences.

So, when a company approached Wrabacon about producing a manual system to inspect, label, and wrap multiple types of candy s, absolute precision and accuracy were major requirements.

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Custom Packing Solution for a Wholesale Artisan Bakery

The Challenge

Corn Cob Transport ConveyorPeople care immensely about the quality of their bread. Everybody loves the aromatic taste, smell, and feel of fresh-baked artisan bread — but few have the patience to prepare it from scratch. While frequenting the local bakery is one option, it’s not convenient for busy people on the move. A good middleground can be found in “parbaking,” wherein a bread product is partially baked, and then quickly frozen for storage. If done correctly, parbaking provides bread lovers with the look, taste, and feel of fresh bread, but none of the stress.

Packaging and providing parbaked artisanal bread products to customers, though, is a great deal more complex. Precision is necessary. Proper timing is everything. That’s why a local wholesale bakery, who specializes in parbaked frozen breads and bread rolls, turned to Wrabacon for solutions.

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Fresh Corn on the Cob, Semi-Automatically Packed

The Challenge

Corn Cob Transport ConveyorWho doesn’t enjoy fresh corn? Easy to cook, affordable, and delicious, corn is an American institution: whether it’s being grilled for an Independence Day barbeque or served beside the Thanksgiving turkey, it’s a wholesome part of the nation’s identity.

That said, while growing corn is one thing, getting it onto store shelves across the nation — husked, packed, and fresh — is another process entirely. It’s not easy. Time is of the essence. Quality is demanded. The machinery itself has to be perfectly timed to match the speed of the human operators who are doing the husking, without missing a beat.

When a regional grocery store chain turned to Wrabacon for help with their corn-packing goals, a custom solution was needed — and Wrabacon delivered.

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Custom CBD Oil Filling System

The Challenge

Wrabacon Custom CBD Oil Filling SystemThe rise of the CBD oil industry is one of the hottest new movements today. CBD, or cannabidiol, is still deemed controversial in some circles, but its usage in treating symptoms such as pain, anxiety, and movement disorders have drawn headlines. As of 2019, insiders have dubbed the growing demand for CBD oil products as “the next gold rush.”

However, manufacturing CBD products — as well as bottling the liquids, in the precise way that CBD oil requires — isn’t easy. Accuracy and meticulousness aren’t just niceties, but requirements, which makes mass production of these products uniquely challenging. That’s why a client turned to Wrabacon to create a system that could pump CBD oil into glass containers at high speeds, while not losing any accuracy. Once filled, the bottles would need to be capped and labeled.

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Frozen Dough Ball Handling System

The Challenge

Frozen Dough SystemMore efficient processes mean more profit. This was exactly the case with a food manufacturer that wanted to increase packaging production for their frozen dough balls. They turned to Wrabacon requesting a system design and install that would receive frozen dough balls from a freezer, singulate them (separate them into individual pieces), and transfer them to two automatic bagging machines. This one change would help them increase their production capabilities dramatically.

Once bagged, the sealed bags would need to be transferred to a manual packing area where the bags were hand packed into shipping cartons. The cases are formed and transferred to the pack off area via another series of conveyors and elevators. Once packed, the cases need to be transferred to the case taper and palletizing area.

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Filling Room Conveyors that Provide Reliability and Flexibility.

The Challenge

Filling Room Conveyors from WrabaconWrabacon was tasked with designing and manufacturing a series of conveyors that transport filled plastic containers from two existing fillers to two existing spot pack machines. The system needed to be designed so that each filler can feed each spot pack machine utilizing reversing belts. The containers will be produced at the rate of 180 per minute per filling machine. After the spot pack machine, spot packs need to be elevated and fed into a new palletizing line at the rate of 30 packs per minute.

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A More Efficient Way to Process & Package Produce

Wrabacon specializes in developing creative packaging & automated conveyor system solutions for our customers that make time intensive tasks efficient and easy. A recent example is a custom designed and manufactured series of conveyors that drastically improved the efficiency of a manual produce packing operation for a regional distributor and specialty packaging company of organic produce.

Client Challenge

The client needed to be able to sort up to 6000 lbs. of produce an hour, grade that produce, and then package it in a variety of ways including loose product, cased product, and bagged product. Prior to the Wrabacon system, the grading portion of the operation was done by opening a box of produce and hand picking the good from the bad and transferring the bad product into a separate box which was then disposed of, which was time consuming and inefficient.

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Wrabacon Inc. is considered an essential business and will remain open during this time. Read more.