Case studies

Conveying lines in production, and what they had to solve

Six projects, in the words an engineer would use: the constraint, the modules that answered it, and the numbers the line runs at today.

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Battery module assembly

A 96 m pallet loop with 14 lift-locate stations

RFID traceability at carrier level and a vertical-lift return over the aisle — see how it was engineered.

Read the case

Logistics & peak flow

Peak-season sortation without recirculation

Mechanical accumulation zones sized for peak flow keep cartons moving when the sorter is full.

Logistics solutions

New energy / Battery

Battery module assembly line — 96 m pallet loop

Double-speed chain pallet loop with 14 lift-locate stations, RFID gates and a mezzanine return using a vertical lift.

96 m loop
±0.1 mm locating
8-week build

Challenge

A tier-1 battery plant needed module and pack assembly on one line, with screwdriving torque data traced to every carrier and no floor space left for buffers between stations.

What BIFA supplied

A BFP double-speed chain loop with accumulating zones replaced the buffers: 14 lift-locate stations pin each pallet to ±0.1 mm, RFID gates write the torque data to the MES, and a BFV vertical lift returns empty carriers over the aisle.

Result

Footprint cut by 18 % — accumulation replaced physical buffers
Traceability down to carrier level, accepted at first audit
Commissioned in 3 weeks on site after an 8-hour FAT

Modules in this line

3C & Electronics

3C electronics test & packing line

ESD belt conveyor network with mini-belt test benches, barcode gates and lift-transfer divert to rework.

ESD-safe
22 stations
12 m/min

Challenge

The customer moved from manual test benches to an in-line flow and could not accept a single ESD defect, nor a line stop to change product mix.

What BIFA supplied

Antistatic PVC belts on anodized frames with conductive wear strips, mini belt test benches fed by lift-transfer units, and barcode gates that route boards to rework without touching the main flow.

Result

Surface resistance held inside the ESD window at every station
Product changeover without stopping the line
Rework loop separated from the main flow

Modules in this line

Logistics & distribution

E-commerce sortation infeed — 260 m

Roller conveyor network with powered 90° curves, multi-wedge zones and accumulation feeding a cross-belt sorter.

260 m network
4,200 pcs/h
6 curves

Challenge

An integrator needed a sortation infeed that could absorb peaks from six packing stations without recirculating cartons back to the sorters.

What BIFA supplied

Powered 90° multi-wedge roller modules with mechanical accumulation zones, merge nodes sized for peak flow, and two BFV vertical lifts linking the mezzanine to the sorter deck.

Result

4,200 pcs/h sustained infeed at peak
Zero-pressure accumulation stops carton damage
Modules shipped in three lots matched to site milestones

Modules in this line

Home appliance

Appliance final assembly & test

Pallet conveyor with indexing stops, robot screwdriving cells and reject gates served by lift-transfer units.

36 pallets
2 robots
99.2% OEE

Challenge

Two robots and twelve manual stations had to work on the same flow, with the appliance held hard enough for screwdriving and vision inspection.

What BIFA supplied

A BFP pallet loop with indexing stops at the manual stations and lift-locate units under the robot and vision cells; reject gates are served by BFTU units so a failed unit leaves the loop without stopping production.

Result

99.2 % OEE measured over the first six months
One pallet design carries four appliance sizes
A single spare-parts kit covers all 36 pallets and drives

Modules in this line

Food & beverage

Beverage filling hall — flexible top chain

Washdown stainless flexible chain layout linking filler, labeller, shrink-wrappers and palletiser in a single drive run.

SUS304 wet area
5 machines linked
1 drive per run

Challenge

Five machines from four suppliers had to be linked in a hall with daily washdown and almost no free floor space.

What BIFA supplied

A BFRXL flexible chain layout with 175 mm and 263 mm chains, 90° and 180° disc curves, hygienic wear strips and sloped drainage — one drive carries the whole run, curves included.

Result

Layout closed in a hall 40 % narrower than the original plan
Washdown-ready, no water traps at transfer points
Changeover to a new bottle format without new modules

Modules in this line

Personal care & pharma

Pharma cartoning infeed — 8 timing belt lanes

Eight independently driven timing belt lanes feeding a cartoner, each speed-matched to the machine.

8 lanes
±0.2 mm spacing
Gentle handling

Challenge

Small cartons had to be spaced to the cartoner pocket pitch with no slip, while the operator loads the lanes by hand and must be able to stop any single lane.

What BIFA supplied

Positive-drive PU steel-cord timing belts — tooth engagement instead of friction — on eight separately driven lanes with hand-load infeed, low-level sensors and lane-level stop buttons.

Result

Spacing held at ±0.2 mm at production speed
Rejects from lane misalignment eliminated
Operator can stop and reload one lane while the rest run

Modules in this line

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