Low-profile ergonomic conveyors save space in busy Jelly Belly factory

Food & Drug Packaging, Nov, 1998

Everybody loves a Jelly Belly[R], the original gourmet jelly bean. From the Oval Office to the playground and everywhere in between, these confectioneries represent taste, style and quality in the candy world. They're so popular that the maker--Herman Goelitz Co.--sends more than 140,000 pounds of the treats out of its Fairfield, Calif., facility every day, running three shifts a day, six days a week.

Since space is limited within the plant, the company needed an efficient system for moving jelly beans through filling, case packing, coding and shipping, which it found with low-profile conveyors from Dorner Manufacturing Inc.

Keeping A Low Profile

Although the plant has 217,000 square feet of space, it also processes large volumes--39 regular flavors plus specialty, seasonal and novelty jelly beans. In addition, most of the beans are packaged in selections, which means mixing them in controlled quantities. Much movement is required throughout the plant, through the production, packaging and carton printing processes.

"The low height of the conveyors," says maintenance manager Marcus Harris, "lets us stack them above one another. In places, you'll find three products going in three different directions, all in the space usually taken by one standard case conveyor."

In the plant, 28 conveyors serve 14 packing lines. On most lines, jelly beans are either case-packed in 10-pound quantities or in small point-of-sale pouches ranging from 2 to 48 ounces, which are then packed 12 to 72 to a case. These cases vary in dimension from 10 x 6 x 6 to 18 x 14 x 6 inches. Three lines pack larger (10- to 25-pound) cases. One line is used for specialty packing in caddies, jars, tins and other containers, and another line is dedicated to hand-packing fragile items. Because of the variety of Jelly Belly flavors, the longest production run of any of the lines is only about 20,000 cases.

"Our 24-hour-per-day production regimen leaves little time for downtime," says Harris. "But these are low-maintenance conveyors. Regular lubrication and a strict preventive maintenance program keep them running around the clock."

The Dorner conveyors are also ergonomically correct. "Their low profile means workers don't have to stretch or reach as far, and the number of them we have been able to fit in saves the workers steps," says Harris. And, he points out, comfort and ease of work are essential to maintaining high production levels.

Delivers Smooth Operation

The conveyors also carry cases through coding, where cases are marked with identifying bar codes and lot numbers, then through a sophisticated printing loop where essential product information is printed for any of the 2,000 possible product combinations. Ingredient statements, number and type of packages, flavors and net weight are printed on each case. Some ingredient lists are so lengthy that type fonts as small as one fifth of an inch are used.

Printing, done by Marsh ink jet printers, at speeds of one case every 1.33 seconds, requires smooth, level conveying for the clear printed result that is essential. "Smooth conveyor travel is important," says Harris. "Dorner delivers in this department as well."

For more information from Dorner Manufacturing, call (800) 397-8664 or Circle 582. For information from Marsh Co., call (618) 234-1122 or Circle 583.

In a nutshell

Goal: Get the maximum conveying capability in the minimum space

How: Install low-profile conveyors

Result: Support for high production, with smooth, ergonomic conveyors