{"id":4866,"date":"2026-03-24T14:24:14","date_gmt":"2026-03-24T14:24:14","guid":{"rendered":"https:\/\/sharp-curie.104-254-244-146.plesk.page\/?p=4866"},"modified":"2026-06-01T15:20:35","modified_gmt":"2026-06-01T15:20:35","slug":"maintaining-production-when-packaging-lines-go-down","status":"publish","type":"post","link":"https:\/\/kraken.geekcertified.com\/?p=4866","title":{"rendered":"Maintaining Production When Packaging Lines Go Down"},"content":{"rendered":"\t\t<div data-elementor-type=\"wp-post\" data-elementor-id=\"4866\" class=\"elementor elementor-4866\" data-elementor-post-type=\"post\">\n\t\t\t\t\t\t<section class=\"elementor-section elementor-top-section elementor-element elementor-element-61b1b195 elementor-section-boxed elementor-section-height-default elementor-section-height-default\" data-id=\"61b1b195\" data-element_type=\"section\" data-e-type=\"section\">\n\t\t\t\t\t\t<div class=\"elementor-container elementor-column-gap-default\">\n\t\t\t\t\t<div class=\"elementor-column elementor-col-100 elementor-top-column elementor-element elementor-element-289d801\" data-id=\"289d801\" data-element_type=\"column\" data-e-type=\"column\">\n\t\t\t<div class=\"elementor-widget-wrap elementor-element-populated\">\n\t\t\t\t\t\t<div class=\"elementor-element elementor-element-88e3fce elementor-widget elementor-widget-heading\" data-id=\"88e3fce\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"heading.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t<h1 class=\"elementor-heading-title elementor-size-default\">Maintaining Production When Packaging Lines Go Down<\/h1>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t<section class=\"elementor-section elementor-top-section elementor-element elementor-element-3ecc2355 elementor-section-boxed elementor-section-height-default elementor-section-height-default\" data-id=\"3ecc2355\" data-element_type=\"section\" data-e-type=\"section\">\n\t\t\t\t\t\t<div class=\"elementor-container elementor-column-gap-default\">\n\t\t\t\t\t<div class=\"elementor-column elementor-col-100 elementor-top-column elementor-element elementor-element-7e66bffa\" data-id=\"7e66bffa\" data-element_type=\"column\" data-e-type=\"column\">\n\t\t\t<div class=\"elementor-widget-wrap elementor-element-populated\">\n\t\t\t\t\t\t<div class=\"elementor-element elementor-element-860be8f elementor-widget elementor-widget-image\" data-id=\"860be8f\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"image.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<img fetchpriority=\"high\" decoding=\"async\" width=\"800\" height=\"442\" src=\"https:\/\/kraken.geekcertified.com\/wp-content\/uploads\/2025\/02\/multi-lane-merg-div-4.png\" class=\"attachment-large size-large wp-image-4255\" alt=\"\" srcset=\"https:\/\/kraken.geekcertified.com\/wp-content\/uploads\/2025\/02\/multi-lane-merg-div-4.png 1016w, https:\/\/kraken.geekcertified.com\/wp-content\/uploads\/2025\/02\/multi-lane-merg-div-4-300x166.png 300w, https:\/\/kraken.geekcertified.com\/wp-content\/uploads\/2025\/02\/multi-lane-merg-div-4-768x424.png 768w\" sizes=\"(max-width: 800px) 100vw, 800px\" \/>\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-20a9d926 elementor-widget elementor-widget-text-editor\" data-id=\"20a9d926\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<p><span style=\"font-weight: 400;\">A food manufacturer approached Kraken Automation with a critical downstream packaging challenge. Frozen product was being delivered from <\/span><b>three wrappers into three cartoners<\/b><span style=\"font-weight: 400;\">, but the existing system had little flexibility. If one wrapper or cartoner stopped, the entire line lost throughput and production targets could not be maintained.<\/span><\/p><p><span style=\"font-weight: 400;\">The customer\u2019s goal was clear: develop an automated system capable of maintaining <\/span><b>220 products per minute<\/b><span style=\"font-weight: 400;\">, even if one of the three lanes went down. The system needed to dynamically adjust speeds, redirect product between lanes, and merge product streams as needed\u2014all while operating within a <\/span><b>limited plant floor footprint<\/b><span style=\"font-weight: 400;\">.<\/span><\/p><p><span style=\"font-weight: 400;\">To fully define the requirements, the customer presented <\/span><b>16 different production scenarios<\/b><span style=\"font-weight: 400;\"> the system needed to handle. Each scenario accounted for different combinations of wrappers and cartoners being offline. Regardless of the situation, the line needed to continue running at production rate.<\/span><\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-6c722568 elementor-widget elementor-widget-heading\" data-id=\"6c722568\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"heading.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t<h2 class=\"elementor-heading-title elementor-size-default\">Engineering the Solution<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-4e46bf4 elementor-widget elementor-widget-text-editor\" data-id=\"4e46bf4\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<p><span style=\"font-weight: 400;\">Kraken evaluated the application from a system integration standpoint, focusing on how to maintain stable product flow under multiple operating conditions. The engineering team determined that a series of <\/span><b>inline merge\/divert systems<\/b><span style=\"font-weight: 400;\"> would provide the flexibility required to route product between lanes and keep the line operating at target speed.<\/span><\/p><p><span style=\"font-weight: 400;\">Both the mechanical and controls engineering teams collaborated to develop a coordinated system that could automatically manage product routing based on the status of upstream wrappers and downstream cartoners.<\/span><\/p><p><span style=\"font-weight: 400;\">The resulting design allowed the system to:<\/span><\/p><ul><li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Operate at full rate when all three lanes were running<\/span><\/li><li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Automatically divert product when a wrapper or cartoner went offline<\/span><\/li><li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Merge product streams to maintain throughput with fewer active lanes<\/span><\/li><li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Adjust line speeds dynamically as conditions changed<\/span><\/li><\/ul>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-53aacdc1 elementor-widget elementor-widget-heading\" data-id=\"53aacdc1\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"heading.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t<h2 class=\"elementor-heading-title elementor-size-default\">Designing for Real-World Operation<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-bf9596e elementor-widget elementor-widget-text-editor\" data-id=\"bf9596e\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<p><span style=\"font-weight: 400;\">During the design phase, the customer introduced an additional requirement: the system needed to allow <\/span><b>operator walking access through the line<\/b><span style=\"font-weight: 400;\">.<\/span><\/p><p><span style=\"font-weight: 400;\">This meant several areas of the system required <\/span><b>walk-through access points<\/b><span style=\"font-weight: 400;\"> that would allow operators to move safely through the equipment. Kraken incorporated <\/span><b>pull-nose conveyor sections<\/b><span style=\"font-weight: 400;\"> at these locations so conveyors could be temporarily stopped and restarted without disrupting the broader production flow.<\/span><\/p><p><span style=\"font-weight: 400;\">The controls architecture was designed to allow these areas to pause and resume operation while the rest of the system continued to function normally\u2014ensuring production stability without requiring manual intervention.<\/span><\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-05adbab elementor-widget elementor-widget-heading\" data-id=\"05adbab\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"heading.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t<h2 class=\"elementor-heading-title elementor-size-default\">System Configuration<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-a6fcac5 elementor-widget elementor-widget-text-editor\" data-id=\"a6fcac5\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<p><span style=\"font-weight: 400;\">The final integrated system included:<\/span><\/p><ul><li style=\"font-weight: 400;\" aria-level=\"1\"><b>Three merge\/divert systems<\/b><span style=\"font-weight: 400;\">, each with independent control panels supplied by Kraken<\/span><\/li><li style=\"font-weight: 400;\" aria-level=\"1\"><b>Two pull-nose conveyors<\/b><span style=\"font-weight: 400;\"> to allow safe walk-through access<\/span><\/li><li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Multiple <\/span><b>product transport conveyors<\/b><span style=\"font-weight: 400;\"> integrated into the system layout<\/span><\/li><li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Interface signals between Kraken equipment and other customer-controlled machinery on the line<\/span><\/li><\/ul><p><span style=\"font-weight: 400;\">Kraken\u2019s experience designing and building merge\/divert systems was central to achieving the required flexibility and reliability.<\/span><\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-589a840 elementor-widget elementor-widget-heading\" data-id=\"589a840\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"heading.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t<h2 class=\"elementor-heading-title elementor-size-default\">Factory Acceptance Testing<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-3606ba2 elementor-widget elementor-widget-text-editor\" data-id=\"3606ba2\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<p><span style=\"font-weight: 400;\">The customer requested a <\/span><b>formal Factory Acceptance Test (FAT)<\/b><span style=\"font-weight: 400;\"> prior to shipment. Over several days, the system was run through the required production scenarios.<\/span><\/p><p><span style=\"font-weight: 400;\">During testing, the customer introduced <\/span><b>additional real-time functional scenarios<\/b><span style=\"font-weight: 400;\">, expanding the original test plan. These scenarios were implemented and verified during the FAT process. Minor control adjustments were identified and resolved at that time.<\/span><\/p><p><span style=\"font-weight: 400;\">The collaborative testing process allowed the customer to validate system performance and build confidence before installation.<\/span><\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-557b148 elementor-widget elementor-widget-heading\" data-id=\"557b148\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"heading.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t<h2 class=\"elementor-heading-title elementor-size-default\">Installation and Results<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-4abe848 elementor-widget elementor-widget-text-editor\" data-id=\"4abe848\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<p><span style=\"font-weight: 400;\">Following the FAT, the system was shipped for installation and commissioning at the customer\u2019s facility.<\/span><\/p><p><span style=\"font-weight: 400;\">While only burst testing could be performed during FAT, the installed system demonstrated full operational capability once connected to the production line. The system successfully handled all operating scenarios presented by the customer and maintained the required <\/span><b>220 products per minute production rate<\/b><span style=\"font-weight: 400;\">.<\/span><\/p><p><span style=\"font-weight: 400;\">Most importantly, the line can now continue operating when individual wrappers or cartoners go offline\u2014something that was not possible with the previous configuration.<\/span><\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-c66f47c elementor-widget elementor-widget-heading\" data-id=\"c66f47c\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"heading.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t<h2 class=\"elementor-heading-title elementor-size-default\">Outcome<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-edd9a73 elementor-widget elementor-widget-text-editor\" data-id=\"edd9a73\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<p><span style=\"font-weight: 400;\">With the Kraken system in place, the customer gained a <\/span><b>reliable downstream packaging solution capable of maintaining production under multiple operating conditions<\/b><span style=\"font-weight: 400;\">. The system continues to operate within the required parameters and provides the flexibility needed to keep the line running even when individual components of the process are unavailable.<\/span><\/p><p><span style=\"font-weight: 400;\">For the customer, this means improved production stability, better utilization of existing equipment, and a system designed to adapt to real-world operating conditions.<\/span><\/p><p><a href=\"\/contact-us\"><i><span style=\"font-weight: 400;\">If you would like to see how Kraken can solve your downstream production process problems, call or contact us on our website. <\/span><\/i><\/a><\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t<\/div>\n\t\t","protected":false},"excerpt":{"rendered":"<p>A food manufacturer approached Kraken Automation with a critical downstream packaging challenge. Frozen product was being delivered from three wrappers into three cartoners, but the existing system had little flexibility. If one wrapper or cartoner stopped, the entire line lost throughput and production targets could not be maintained. The customer\u2019s goal was clear: develop an [&hellip;]<\/p>\n","protected":false},"author":2,"featured_media":4255,"comment_status":"closed","ping_status":"open","sticky":false,"template":"elementor_header_footer","format":"standard","meta":{"_acf_changed":false,"footnotes":""},"categories":[8],"tags":[],"class_list":["post-4866","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-automation"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v28.2 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>Maintaining Production When Packaging Lines Go Down | Kraken Automation<\/title>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/kraken.geekcertified.com\/maintaining-production-when-packaging-lines-go-down\/\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"Maintaining Production When Packaging Lines Go Down | Kraken Automation\" \/>\n<meta property=\"og:description\" content=\"A food manufacturer approached Kraken Automation with a critical downstream packaging challenge. 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