Increased profitability by handling containerized sugar directly

Heinz Wattie’s has increased profitability by hundreds of thousands of dollars per year by importing and handling containerized sugar directly.



Equipment: 20ft Flat Deck container unloader, Location: New Zealand, Industry: Food – Sugar.

Challenge
Heinz Wattie’s challenged A-Ward to design and build a container unloader to enable Heinz Watties to switch from purchasing sugar domestically to importing sugar in 20ft containers. This container unloader was required to receive full 20ft containers from swing lift trailers (at a height of 1.35m), rise horizontally to a height to 2.6m (to align and integrate with the GEA Nu-Con material distribution box) and then tilt to up to 50 degrees via an integrated PLC system to unload the sugar. The design also had to enable the container doors to be manually unlatched when in the low position, without interfering with the safety fence.

Solution
A-Ward designed and built a highly-customized Flat Deck container unloader which hydraulically lifts the container up 1.2m and forward 2m at the same time. This system provides enough room for the operator to safely walk between the container doors and material distribution box. The container doors are manually unlatched when in the low horizontal position and then the PLC system kicks in to control the raising and tilting. The container unloader also has a series of 9 Allen Bradley safety switches integrated to ensure total control and safety whilst being operated via the PLC. This unique design provides an extremely stable base for tilting the containers.

Result
Heinz Wattie’s has increased profitability by hundreds of thousands of dollars per year by importing and handling containerized sugar directly. By using a customized A-Ward container unloader, Heinz Wattie’s has been able to maximize operator safety, reduce labor and unload as fast as they desire by adjusting the unloading angle. Another major benefit is that Heinz Wattie’s is able to store containers on the container unloader; removing all truck waiting costs.