Stacks crates onto pallets using a collaborative robot

The Cobot Crate Palletizing system from Van Made is engineered for automated stacking of plastic crates, E-crates, bread trays and other reusable containers. The solution uses a collaborative robot with a custom end-of-arm tool designed for gripping rigid crates with side openings or reinforced lips.

With integrated pallet detection and optional automatic pallet dispensers, the system picks crates from the conveyor and stacks them in the required pattern. The capacity is typically 6–12 crates/min depending on weight and pattern. The cobot’s controlled force and slower safe-speed limits make it suitable for open production spaces where operators still handle wrapping or label checks nearby.

Its compact footprint allows installation directly behind existing production lines with minimal reconfiguration. Pattern templates can be switched from the control panel to accommodate different crate sizes or stacking formats (interlocked, straight, cross-pattern). Optional sensors verify crate orientation and handle deformed crates without causing line stops.

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Separates and Classifies Powders and Granules

The MZM & MZF Multi-Plex Gravity Classifier from Hosokawa Alpine offers a low-maintenance, wear-resistant solution to precise particle separation across various industries. Utilizing a zigzag classifier design, it allows for steplessly adjustable precision of cut, making it ideal for achieving sharp separations in powders and granules ranging from 0.1 to 10 mm. With throughput capacities extending from a few kilograms per hour in lab settings to approximately 200 tons per hour at an industrial scale, this classifier is suitable for applications from fine metal powder production in additive manufacturing to the separation of cracked seeds and pigment particles. PLC controls facilitate seamless integration into automated production lines, while its robust construction withstands diverse operational conditions without requiring extensive maintenance. Available materials ensure durability and compatibility with a range of feed materials. Customization options include multi-tube configurations, enhancing its versatility in handling various particle sizes and feeds.

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Transfers and Arranges Products for Packing

AC Horn Manufacturing offers the Packoff Conveyor System, designed to efficiently facilitate the transfer of snack and nut products from packaging machines to pack-off stations. This system is engineered to address manual labor challenges in the packaging room by gently conveying products like microwave popcorn bags and snack packs to a rotary table for seamless packing. Capable of continuous and high-speed operations, it integrates smoothly into existing production lines, enhancing throughput and minimizing labor dependency. Constructed with durable materials to withstand rigorous food processing environments, and features fully adjustable components for operator comfort and efficiency. The Packoff Conveyor System is suitable for various food and snack industries, ensuring reliable and streamlined product handling and packing.

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Collates and Aligns Snack Products for Packing

The Single Lane Collator from AC Horn Manufacturing efficiently collates and aligns snack food products for streamlined packing processes. Designed to reduce labor and enhance productivity, it accepts bags from the packaging machine and gently conveys them into a sequence for easy grouping and packing. Ideal for applications in popcorn, roasted nuts, and coated nuts, it caters to the needs of snack food manufacturers and nut processing companies. This collator is engineered for continuous, high-speed operation, featuring automated functions that minimize manual handling. Its robust design ensures seamless integration into existing production lines, while options for loose pack configurations enhance versatility. With a focus on reducing operational costs and increasing throughput, the Single Lane Collator is a reliable solution for modern packaging rooms.

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Puffs and Processes Snack Pellets and Nuts

The M420, M449, and M539 puffer systems from AC Horn Manufacturing are engineered for high-capacity puffing in the snack food industry, catering to products like popcorn, peanuts, and chips. These systems are equipped with precision PLC controls to manage airflow and heat, ensuring optimal product expansion and uniform texture. The forced air combustion system, combined with internal laminar baffling and precise burner controls, allows for efficient heating and drying, accommodating a wide variety of pellet shapes and sizes. With throughput capacities reaching up to 1,500 lbs/hr (680 kg/hr), these puffers excel in continuous operations, enhancing productivity for manufacturers.

Designed for easy integration into existing production lines, the puffers feature variable drum and fan speed controls, allowing for detailed customization according to specific product recipes and processing requirements. The robust construction minimizes product trapping, reducing downtime while the extra insulation contributes to low operating costs. Fabricated with high-quality materials, the systems ensure long-term durability and ease of maintenance, with options for additional engineering support and customization to meet particular processing needs.

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Processes and Dries Nuts, Seeds, and Snacks

The Modular Rotary Oven from AC Horn Manufacturing is tailored for snack and nut processing applications, offering a versatile solution to drying and roasting challenges. Its modular design allows linking multiple heating zones for customized temperature and airflow configurations, perfect for processing flavored sunflower seeds, roasted almonds, and extruded corn snacks. With continuous operation capabilities, this oven efficiently manages moisture reduction and flavor infusion through its uniformly welded stainless steel construction, supporting sanitary requirements with easy wash-down access. Capable of handling diverse product types like solids and granules, it integrates seamlessly into existing production lines with options for customization to enhance processing efficiency.

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Applies Oils and Seasonings to Snack Products

AC Horn Manufacturing’s Industrial Seasoning and Coating System is engineered to optimize flavor application in snack production. This system features continuous flow oil applicators and electromagnetic scarf plates for even distribution of oils, seasonings, and slurries. Ideal for producing caramel popcorn, honey-roasted peanuts, and chili lime tortilla chips, it supports various snack food industries. The system’s processing capacity is tailored to meet specific production needs, ensuring seamless integration with existing lines. With options for stainless steel construction, it offers corrosion resistance and durability. Easy to clean and maintain, it connects with CIP systems to minimize downtime. Customization is available for specific product requirements, supported by AC Horn’s experienced engineers.

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Pops and Processes High-Capacity Popcorn Batches

The Platinum Series Dry Popper from AC Horn Manufacturing offers a high-capacity, continuous popcorn production system designed for industrial-scale snack food manufacturers. Utilizing a forced air combustion system with internal laminar baffling and precise burner controls, this popper ensures efficient popping and consistent product quality across various popcorn flavors and coatings. Suitable for applications such as butter-flavored and caramel-coated popcorn, it supports large throughputs with models ranging from 200 to 1,500 lbs/hr. Automated via advanced PLC controls, it seamlessly integrates into existing production lines while minimizing energy consumption and operational costs. Constructed with extra insulation, the equipment is built for durability and reduced maintenance. Optional infeed screw conveyors and sifting tumblers allow for further customization to meet specific production needs. Ideal for both food and snack production industries, this popper guarantees reliable results in continuous, high-volume operations.

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Cooks and Coats Popcorn and Nuts

The M320 Series Popcorn Cooker/Coater from AC Horn Manufacturing delivers precise cooking and coating of snacks through a sophisticated single-process, automatic design. Engineered to suit diverse applications like caramel corn and caramelized nuts, it integrates easily into existing production lines with preprogrammed temperature control and agitation for uniform coating. Capable of processing up to 100 lbs/hr, the M320 Series adapts to various batch sizes and recipes, ensuring high product consistency. With options to transition between products and configurations to meet specific processing demands, this equipment optimizes production efficiency. Constructed from durable materials, it supports enduring performance and ease of maintenance, making it an ideal solution for snack food manufacturers and food processing plants seeking reliable equipment integration and increased throughput.

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Grinds and De-stones Corn for Masa Production

The Stoneless Corn Masa Mill LM-18†from AC Horn Manufacturing revolutionizes masa production with its innovative design featuring proprietary Nihard alloy plates, offering durability and precision unmatched by traditional stone mills. This equipment is designed for seamless integration into high-speed, continuous operations for snack food manufacturers and masa processing facilities. It’s capable of producing between 2,500 and 6,000 lbs/hr of consistent, high-quality masa for making tortillas, chips, and other snacks using a grinding and de-stoning process that eliminates the need for additional downstream equipment. Its robust construction withstands common processing contaminants like rocks and metal, ensuring operational longevity and reducing maintenance frequency. The system includes options such as a cup & cone assembly and a consolidated control panel for customizable processing needs.

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