Label applicators and printer from Avery Dennison Printer Systems have helped Dow Chemical achieve substantial efficiencies at its facility in Freeport, TX, according to Dow Chemical project manager Joe Hairston.
The Freeport facility packages over 100 different chemical products, including glycerine and glycol, in 55 gal metal and plastic drums. Annual output of the fully automated drum-filling and handling operation is approximately 200,000 drums. The chemicals are in liquid form and include hazardous and nonhazardous products.
Prior to early 2001, the drums were filled and labeled using almost completely manual methods. There were six separate filling/packaging lines, staffed by two or three employees each, located in different parts of the plant. Product ID labels were preprinted and hand-applied to drums after filling.
Changeover to Automatic Operation
In spring 2001, Dow Chemical installed fully automated drum-filling and handling equipment supplied by Feige Filling Technology. The six manual packaging lines were consolidated into two automatic lines -- Line A and Line B -- operating side by side. Line A handles nonhazardous chemicals; Line B handles hazardous or flammable chemicals.
At Feige's recommendation, label applicators from Avery Dennison Printer Systems were integrated into the two automated packaging lines. Two AVERY DENNISON™ ALS Series label applicators were installed on Line B; one ALS applicator on Line A.
How the System Works
The Feige drum-handling equipment (pictured) automatically fills and seals the 55 gal metal or plastic drums, one drum at a time. After filling and sealing, the drums are transferred by conveyor to the label applicators. A photoelectric eye on the conveyor alerts the label applicators that drums are approaching and initiates the labeling process.
Product ID labels containing trade name, chemical composition, lot number and other information are printed separately on an as-needed basis and then loaded into the applicators. Because Line B handles hazardous chemicals, two applicators are needed there to apply separate product ID and hazardous materials labels.
Major Benefits
"The automatic system and integrated labelers have led to a substantial increase in efficiency," says Dow's Joe Hairston. Six separate manual drum lines, requiring two or three employees each, have been merged into two fully automatic lines. Labor requirements related to drum filling, handling, and labeling have been substantially reduced. Also, the automatic label applicators have lessened the risk of drum mislabeling.
(Photos courtesy of Avery Dennison Printer Systems)
