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The necessity to spread/separate or converge products while they are moving on a process belt conveyor is a major requirement for a wide range of food, confectionery and industrial applications. In many cases this allows processors to run narrower conveyors saving factory floor space. Coating processes also benefit by separating product and reducing rejection rates.
The necessity to spread, separate or converge products while they are moving on a process belt conveyor is a major requirement for a wide range of food, confectionery and industrial applications. In many cases this allows processors to run narrower conveyors saving factory floor space.
Wire Belt’s answer is a simple positively driven non-slip spreader or converger using Ladder-Flex™ stainless steel belting. The conveyor comprises rows of belting running on a food grade high density blue polyethylene support surface and a series of small stainless steel sprockets driving within the mesh of the belt strands. The conveyors can be custom built to suit the product being handled.
* Please contact Technical Sales to discuss faster applications
The standard design is a ‘fan-type’ spreader or converger which positions product evenly on either side of the conveyor centreline.
Our standard drive motors and controllers are supplied with IP66 enclosure protection and OS2 surface protection (drive motor only) to ensure suitability for intensive wash down processes. If required, customer specified drive systems can be fitted to suit each individual application.
A variable-frequency drive (VFD) can be fitted alongside the drive motor to provide a stop/start function and speed control. As standard, this is housed inside our Standard Conveyor Control Panel, featuring a fully stainless steel enclosure and emergency stop button. Alternatively, an Invertek E3 Optidrive controller can be supplied with plastic enclosure and no emergency stop function.
As standard, Ladder-Flex™ conveyors are supplied with height adjustable footpads with fixing holes. As an optional extra, Ladder-Flex™ conveyors can be supplied with lockable, swivel castors with brakes.
Conveyor frame construction from stainless steel. Support surface is high density food grade blue polyethylene.
Our esteemed customer, a significant player in global End-of-line (EOL) Packaging Automation for the food industry, sought a specialised solution for a challenging secondary packaging application in their fast-paced ice cream production line. Grappling with spatial constraints and distinctive product flow challenges, they needed a conveyor system seamlessly integrating with their robotic packaging solution.
With over 40 years of industry leadership, our customer is a cornerstone in EOL packaging automation, serving giants in global food processing. Having collaborated on numerous occasions, Wire Belt, shares a robust relationship with the customer, intimately understanding their industry nuances and challenges.
The project encompassed a large, intricate packaging line with irregularities at an intersection, causing disruptive product flow and hindering downstream robotic operations. The challenge was to engineer a conveyor system to fit seamlessly within the line, accommodating changes in width and height without compromising product integrity, all within a confined space.
Wire Belt engaged in close collaboration with the customer to comprehend intricate parameters. The Ladder-Flex conveyor emerged as the ideal solution for efficient product spreading but required a custom frame for a gentle 10-degree decline without compromising structural integrity. Drive components, drive shafts, leg assemblies and motor housing also had to be redesigned to reduce the overall conveyor width, aligning precisely with the client’s specifications.
Though this customisation extended lead times and incurred additional costs, Wire Belt, unwavering in its commitment to client satisfaction, was versatile in meeting the revised requirements. The final conveyor was delivered three weeks ahead of the revised estimated date.
The tailored Ladder-Flex conveyor seamlessly addressed the change in line parameters, ensuring precise infeed and outfeed dimensions within the available space. Empowered by this solution, the customer executed their project for a major frozen desert producer, meeting deadlines and budget constraints.
In the dynamic realm of food processing, Wire Belt’s century-long expertise is unparalleled in balancing industry challenges, budget constraints, and quality considerations. Wire Belt’s range of metal conveyor belts and conveyors offer both standard and tailored solutions. The Ladder-Flex conveyor is a testament to their commitment to overcoming unique challenges, ensuring optimal performance for clients.
For further enquiries or to explore Wire Belt’s comprehensive product range, please contact sales@wirebelt.co.uk or visit www.wirebelt.co.uk.
Wire Belt: Your Trusted Partner in Metal Conveyor Solutions.
A Ladder‑Flex conveyor is a specialised type of spreading, converging, or diverging conveyor system used primarily in food processing, confectionery, and other industries where products need to be gently separated, aligned, or grouped while moving along a production line.
Ladder-Flex conveyors use rows of single chains to gently guide products into position through spreading, converging or diverging. This design allows for precise spacing and orientation, making them ideal for downstream processes such as packaging, inspection or robotic pick and place.
Unlike standard belt or roller conveyors, Ladder-Flex offers superior control over product alignment. Its unique design allows for delicate or irregularly shaped items to be handled effectively, minimising risk of damage and therefore ensuring high product quality.
Ladder-Flex conveyors are ideal for lightweight or delicate products, as well as areas where processing widths are not consistent. Common sectors include baked goods, confectionery, protein processing or the introduction of pick and place equipment.
You’ll find Ladder-Flex conveyors in food processing and packaging facilities, anywhere where hygiene, precision and gentle handling are essential.
The Ladder-Flex conveyor system can efficiently and effectively increase or decrease the spacing between products, without the need for operator input. The individual chains can be used for randomised products or lanes of grouped chains for consistently spaced products. This improves accuracy in packaging and inspection and reduces the risk of product sticking, jams or misfeeds, meaning fewer rejects and improved efficiency.
Absolutely, Ladder-Flex conveyors have been designed using the latest EHEDG conveyor design guidelines and feature open frame construction and stainless steel components, making them easy to clean and ideal for hygiene sensitive environments. Their simple mechanical design also means fewer parts to maintain.
Integration is simple and highly adaptable. Ladder-Flex conveyors are designed to be customised to fit seamlessly into your existing layout and are compatible with most upstream and downstream equipment, including pick and place and robotic systems. This flexibility helps optimise production line configurations and enhances product handling efficiency.
Incline and decline options are available depending on the application and our experienced technical sales team provides full support throughout the entire process, from design and ordering to installation and commissioning, ensuring a smooth and successful integration.
Customers consistently report smoother operations, better product presentation and reduced waste. Many have seen improvements in line efficiency and packaging accuracy after switching to Ladder-Flex.
By ensuring consistent product spacing and orientation, Ladder-Flex reduces downtime, improves throughput and enhances overall line performance, delivering a strong return on investment.
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