Baking&Snack - February 2012 - 97

TRENDS

FORMULATION

EQUIPMENT

OPERATIONS

SPECIAL REPORT

Pan Management
by Shane Whitaker

Robots come to the rescue with automated stackers/unstackers and storage and retrieval systems that handle pans more gently in a smaller footprint.

For wholesale bakeries wanting to minimize safety risks to employees, pan handling represents an area to reduce several worker safety hazards. Whether it’s working around hot metal objects that can cause burns or lifting and moving pans repeatedly that risks repetitive motion injuries, manual pan handling can be a precarious task. Many bakeries have increased their SKUs, thus making the job more difficult to move pans on and off lines or to store and retrieve them without assistance of automated equipment. “I think a bakery is in need of an automatic pan storage/retrieval system when there are multiple pan types involved and multiple changeovers required,” said Frank Achterberg, president, Capway Systems. York, PA. As bakeries increase line speeds with larger pans, they risk greater chances for workers to sustain back injuries, according to Billy Rinks, national sales account manager, Stewart Systems, Plano, TX. Larger plants operating around the clock may gain the most from automated pan handling systems. However, Charles Gales, manager, automation sales, Weldon Solutions, York, PA, said, “even smaller bakeries with only occasional pan change-

overs can benefit from automation by keeping their employees focused on higher value-added tasks than moving 20 to 30 pans per minute.” Most automated pan systems have a return on investment of three years or less, added Roland Lomerson, vice-president of automation, AMF Bakery Systems, Richmond, VA.

Minimizing pan damage
The greatest benefits from automated pan handling systems include less worker fatigue, faster rates and less damage to pans and their glazing, according to Mr. Rinks. “These three factors are the basis for determining return on investment,” he said. “It differs from bakery to bakery, but a good rule of thumb would be two to five years based on how much automation is done.” Stewart manufactures pan stackers/unstackers as well as conveyors to move pans from point A to point B. Its stackers/unstackers can include features such as fully recipedriven machines to light curtains for personnel safety. Bakeries can setup the stackers/unstackers to either interface with manual pan trucks or automatic storage and retrieval systems. Additionally, Mr. Rinks noted Stewart’s machines include inverter-

controlled motors for soft starts and stops to gently handle the pans. The Capway RoboCap features a gantry-style robot that unstacks, stacks, stores and retrieves pans all within the same unit. “The advantage is that only one system is required for all the operations required,” Mr. Achterberg said. “The large gripper allows multiple pans to be picked up at one time, therefore reducing the cycles the robot has to perform.” By stacking and unstacking the pans vertically, Capway’s system handles pans gently and does not touch or damage the coatings in the pans, thereby extending pan and pan coating life.

Designed for stacking and unstacking pans as well as their storage and retrieval, gantry-style robot systems handle various types of pans in a compact footprint.
Capway Systems

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February 2012

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Baking&Snack - February 2012

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