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Edward A. Bianchi, PE
Consulting EngineerSelected Examples of Projects
UNITIZING MODERNIZATION
US$2,767,000
Replaced two obsolete unitizers and stretch wrappers with new, high-speed equipment capable of 140 unit-loads per hour, total. System included low-pressure case accumulator infeed conveying, orbital stretch-wrapping, and automatic double-stacking of unit-loads. Developed and installed custom case sortation system to send any load to any unitizer, up to three loads simultaneously. Specified and installed unit-load conveying and accumulation system over 600 feet long, with capacity for storing 78 double-stacked unit-loads. System featured DeviceNet networking. Demolished 550 feet of existing interior rail siding, repaired corroded/spalled building foundation piers, filled and compacted, and installed new reinforced concrete floor. All work done with minimal disruption of ongoing warehouse and plant operations.
HIGH-SPEED CARTONING, TRAYPACKING AND MULTIPACKING
US$1,606,000
Replaced three obsolete volumetric cartoning machines and manual traypacking with two high-speed cartoners (400/min each) and semi-automatic traypacking. Achieved the cost savings to justify the project by developing and implementing a custom weight-control feedback system. Developed semi-automatic traypacking stations capable of sustained rates of 200 cartons per minute, with peak rates of 400 cartons per minute. Integrated a fully-automatic multipacking infeed and overwrapping system into the line, reducing multipack line staffing from 13 operators to three.
SEMI-AUTOMATIC CARTONING
US$511,000
Eliminated back and wrist repetitive motion injuries by providing mechanical assistance to cartoning personnel. Developed semi-automatic cartoning stations, specially adapted for the product and cartons. Developed and tested prototypes at the plant with maintenance personnel, then specified, purchased and installed production equipment obtained from custom equipment vendors. Line achieved 110% of standard on fourth day of startup.
SYRUP PIPELINE REPLACEMENT
US$152,000
Replaced existing corn syrup pipeline from receiving to remote storage tank, and from storage tank to production floor. Purged and cleaned existing pipe prior to removal. New pipe heat traced, insulated and passivated. Specified and installed new pressure relief system to prevent overpressure damage to new pipe. All work done to a rigid production line shutdown schedule.
BAG-IN-BOX UPGRADE
US$91,000
Improved existing automatic bag-in-box packaging system to achieve the level of performance two previous projects, by others, had failed to deliver. Solution included two servo-operated "smart belts" and an innovative bag-flattening system. Production rates were increased from 55-75 packs/minute to 85-95 packs/minute, exceeding the project goals. The revised system achieved 120% of standard during the second week of startup.
PRESSURE STERILIZATION FACILITY DESIGN STUDY
Conceptual development, layout, preliminary costing and computer simulation of a super-high-pressure meat sterilization facility. Included proposal of an automated transport and pressure-vessel loading system for 200kg baskets of product, and a robotic pick-and-place system for transferring baskets to and from the manual loading/unloading station. Created a discrete-event computer simulation of the basket handling and pressure treatment process in Witness 2001, and used it to evaluate alternate strategies for system redundancy and maintenance. Designs featured in presentation at client's annual stockholder meeting.Edward A. Bianchi PE
Packaging Systems ⇔ Automation ⇔ Machine Design
EdwardBianchiPE@aol.com
717-649-5251
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