1.- Background
2.- The Challenge
3.- The Solution
4.- Results & Benefits
5.- Conclusion
Background
A leading bakery needed to increase the production capacity of one of its most popular artisanal bread products. To achieve this, the customer planned the installation of a new production line. Rexfab was commissioned to design and install the product handling system from the cooling towers to the post-packaging area.
The line needed to handle two very different SKUs—each with distinct sizes and characteristics—which posed a significant engineering challenge. While the production rates were within the standard range for an automated artisanal bread line, the complexity lay in ensuring smooth, reliable transport of the variable products.
The Challenge
The primary constraint was space. Integrating the cooling tower, packaging system, and case loading station within a tight layout required an innovative solution. Additionally, the system had to be designed for future scalability and seamless integration with other OEM equipment, without compromising on performance or footprint.
The Solution
Rexfab engineered a customized conveyor system that reflects the company’s iconic design quality and commitment to reliability. The solution featured:
- A robust L transfer directing product flow toward a slat diverter, allowing controlled distribution of product.
- A space-saving vertical switch immediately following the slat diverter—this was the breakthrough element of the design.
This vertical switch was developed to:
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- Feed potential new slicers and baggers.
- Save critical floor space.
- Maintain precise control over the flow and granularity of individual bread units.
- Enable the feeding of multiple downstream lines—achieving results typically requiring larger, more complex diverter systems.
Results & Benefits
- Space Optimization: The vertical switch minimized the footprint of the distribution system while maximizing flexibility and control.
- Scalability: The design supports future capacity increases and the addition of new packaging equipment.
- Integration: The system was seamlessly integrated with existing and new OEM equipment, ensuring smooth operation across the entire line.
- Project Excellence: Rexfab’s experienced project management team provided end-to-end support, ensuring on-time delivery and a smooth commissioning process.
Conclusion
With this project, Rexfab demonstrated its expertise in turning spatial and logistical constraints into opportunities for innovation.
The customized conveyor system not only addressed the customer’s immediate needs but also provided a scalable, efficient foundation for future growth of a high-potential product line.
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