Berry (Kerr) Plastics

Injection Molding Case Study

Business Objectives

  • Update Berry/Kerr's manual process of distributing prescription vials
  • Reduce labor time and cost
  • Keep the plastic injection molding machines running


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Helping Berry (Kerr) Update Manual Processes to Reduce Labor Costs

Berry Plastics manufactures and distributes prescription vials for several drugstore chains and superstores. Bastian Solutions helps Berry to singulate the vials as they come out of the injection molding machines. The vials are then counted into routed cartons and ultimately automatically checked for quality, sealed, and labeled for shipment. The system interfaces with J.D. Edwards ERP and has saved a tremendous amount of labor from the previous manual process.

Berry Plastics System Illustration
 

Key Technologies

  • Automatic Vial Singulators
  • Interface to Mold Injection Machines
  • Weigh Verification for quality control
  • Air Conveying System - uses blowers to gently transport vials from high production vial mold injection machine. Cost effective for relatively long distances
  • Automatic Carton Erectors
  • Print and Apply On Demand
  • High Speed Communication Protocols - profibus, RS232, devicenet
  • Interface to MATTEC manufacturing scheduling software
  • Routing and production inventory tracking software
 

See the results

The new system interfaces with J.D. Edwards ERP and has saved a tremendous amount of labor from the previous manual process


Bastian's solution allowed Berry/Kerr to singulate vials as they came out of the injection molding machine. They were able to be immediately counted into routed cartons, automatically verified, and sealed and labeled for shipment

 

Photos of our solution

Interested in automated singulation technology? 
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