This is a one-up machine that makes a crust-less sandwich. The machine operates continuously. The bread is sliced lengthwise and placed on the “tray”. Then fillings are placed on one half of the bread slice. The bread is folded over and the crust is then trimmed off. The finished product is removed at the end and the crust rolls around to a container underneath. Construction is stainless steel. The machine is wash-down rated.
This machine does a similar function to the continuous crimp machine. In this machine, fillings are already placed between two slices of bread. They are loaded onto the conveyor four at a time. When the machine indexes the four sandwiches are moved under the crimp area. There, they are crimped, cut and the crust is stripped off.
To see the index crimper in action, visit http://www.youtube.com/watch?v=ltbf4WMvRU4
Keystone was contracted to build a specialized machine for a major pharmaceutical supply company. The machine punched two holes in two different locations on two different type vial stoppers. The stoppers are about ½” in diameter and the holes are around 1/8” in diameter. The machine is hand loaded at the present time but is capable of being loaded automatically from a bowl feeder in the future. Stoppers are loaded into an indexing conveyor. A transfer picks up two stoppers and loads them in a rotary fixture while unloading finished stoppers and dropping them in a discharge chute. The rotary transfer indexes the stoppers under the punch where they are punched, rotated either 180 degrees or 140 degrees and punched again. Cycle time per stopper is 20 seconds. The machine received a very thorough acceptance and validation.
We provided a unique machine to saw frozen dough. A rectangular piece of dough is placed in one end and pushed into the saw. Three cuts are made to trim off the outer edges. It is then pushed through five saw blades in the other direction. At the end of the saw there are 10 smaller uniform slices of dough. A temporary press was made due to the rush and urgency of delivery. It is shown as well. Both machines use stainless, aluminum and plastic components for wash-down.
We were contracted to develop a new method of counting candy. The previous system used a weigh scale to randomly mix candy by weight. The marketing people wanted to have an exact count of candy using 6 different flavors in a 40 count container. We built different prototype machines to test different concepts.
We tried vibratory feeders but were unable to separate them fast enough for production. We built “speed up” conveyors to separate and count them but they were traveling too fast at the end and we were concerned with product damage.
One of our engineers brought in an old treadmill. We elevated it, added some pins to the tread belt and used cardboard guides to test the concept. It worked. We then built a prototype machine and tested it extensively. The specification was 1000 pieces counted plus or minus 1. It passed and we built 5 more machines.
Each machine has four hoppers with an individual weigh scale. It tares on startup and at specified intervals. Each of the 6 machines drop their load of candy into a special indexing conveyor we engineered. When it reaches the end, the 40 pieces of candy drop into the container.
Previously we built a complete fill line for a candy manufacturer in Scranton, PA. It separates buckets, fills them, tamps the product, lids the bucket and labels it. Their productivity was increased by 72% with a 12% reduction in manpower. One picture of that line is included.
We were contacted by a Bio-Med manufacturer in upstate NY to develop an inspection machine for a new product. There are 400 holes in a one square inch area on silicon wafers. They needed to determine the diameter of the holes to a sub-micron level with the holes themselves being under 10 microns in diameter. We used a high resolution vision system with a 1500 to 1 lens to inspect the holes. The wafer is positioned using linear motors under the camera lens. If a hole is out of position, the position on the screen is transmitted to the controller and the wafer is repositioned to center the hole. The camera is focused and the data from the camera is recorded. Data includes light intensity, pixel count, position and resolution. Each set of 400 holes is recorded until the wafer is fully inspected. While reviewing the data, a specific hole can be repositioned and re-inspected. After review is complete, the data is transferred to an Excel spread sheet for future reference. Each set of 400 holes has a unique ID number. We used an Allen-Bradley ControlLogix 5000 PLC motion system and Keyence camera.
Our brochure is included for review.