Alba Manufacturing - The Half Ton Conundrum

In the ever-evolving landscape of the auto parts industry, efficiency, and innovation reign supreme. Every minute saved in the production process translates to increased productivity and ultimately, a competitive edge. When one of the leading auto parts manufacturers faced the challenging task of processing large volumes of bumper covers, they turned to Alba Manufacturing and their integration partner, Ingalls Conveyors, Inc., for a solution to streamline their operations. The result? An innovative palletizing line that dramatically transformed their manufacturing process.
The challenge: processing a large volume of bumper covers efficiently with limited resources. The auto parts manufacturer required multiple processing stations but only had two de-stacker systems available. Handling the bumper-filled, heavy metal modules (90” wide x 48” long x 36” high at 1,000 lb. each) was an ergonomic nightmare. Additionally, there was the complex task of rotating the cumbersome modules 90 degrees to ensure the order picker could access them in the correct orientation. It was clear that a conventional approach would not suffice.
Alba Manufacturing, renowned for its expertise in material handling solutions, rose to the occasion. Collaborating closely with their integration partner, Ingalls Conveyors, Inc., they devised a unique system tailored to their manufacturer’s specific needs.
The cornerstone of the solution was Alba's innovative metal module de-stackers, which efficiently distributed the modules to the various workstations using a series of chain transfers and through-frame/through-drive side transfers. This design allowed the manufacturer to maximize the utilization of their existing resources while maintaining optimal workflow.
However, the true game-changer -- incorporating lift and rotate units, strategically positioned to change the orientation of the modules for ease of pickup in the conveyor system. These units enabled seamless module orientation, eliminating the ergonomic challenges associated with manual rotation. Previously, operators had struggled to maneuver the large, unwieldy half-ton modules on ball transfer tables, leading to inefficiencies and potential safety hazards. With the lift and rotate units, this cumbersome task was reduced to the simple push of a button, significantly enhancing operational efficiency, worker safety and satisfaction.
Moreover, Alba Manufacturing's commitment to innovation was evident in the incorporation of value-added features such as the through-transfer, low-elevation, drive design and oversized lift and rotate units. These features not only enhanced the performance and versatility of the system but also underscored Alba's dedication to delivering solutions that exceed customer expectations.
The benefits of the collaboration between Alba Manufacturing and Ingalls Conveyors, Inc. were profound. By leveraging their expertise and innovative technologies, they transformed the auto parts supplier's manufacturing process, enabling them to meet the demands of a rapidly evolving industry with newfound unparalleled efficiency and safety.
VALUE ADDED FEATURE(S)
Through transfer low elevation drive design, and oversized lift and rotate unit
Alba Manufacturing is your full-service conveyor manufacturer for all your pallet handling applications. Call us to locate your nearest Alba Partner Network Member to assist with your next project at 866.252.2634 or visit our website at www.albamfg.com.