How to Prevent Tray Jams in Automated Packaging Lines
A tray jam doesn’t seem like a major problem until it stops your entire production line.
Containers sticking together. Trays feeding inconsistently. Misaligned products causing backups downstream. These issues cost manufacturers time, labor, and production efficiency every single day.
The good news? Most tray jams are preventable with the right denesting solution.
Why Tray Jams Happen
Not all containers are designed the same. Some trays have compressed flanges. Others stick together because of material type, inconsistent stacking, or static buildup. Lightweight containers can shift during production, while molded fiber and paper products can create separation challenges.
When your denester isn’t designed for your specific container, problems start quickly:
- Inconsistent spacing
- Misfeeds
- Double picks
- Downtime for manual intervention
- Reduced production speeds
These issues only become more expensive as line speeds increase.
The Right Denester Makes All the Difference
The best way to prevent tray jams is to match the denesting system to your exact container and application.
At FEMC, we engineer denesting equipment around real-world production challenges, including:
- Containers that stick together
- Difficult tray orientations
- High-speed production environments
- Delicate or irregular packaging
- Rigid containers and molded fiber products
Whether you need a Universal Screw Denester, Pick-and-Place Denester, Pick-and-Slide Denester, or a fully custom solution, the goal is the same: accurate placement and reliable performance without slowing down your line.
Why Sample Testing Matters
Every container behaves differently in production.
That’s why FEMC encourages manufacturers to send samples for testing and validation before investing in a denesting solution. Our team can evaluate your trays, cups, lids, or containers and recommend the best system for your application.
In many cases, solving tray jams starts with understanding how your containers actually perform at production speed.
Stop Fighting Tray Jams
Stop losing production time to misfeeds, inconsistent spacing, and containers that won’t cooperate. Send FEMC your trays or containers for testing, and our team will help identify the right denesting solution for your application.
At a recent America Makes Members Meeting Exchange, Wax shed light on the 14 essential technology domains pinpointed in the National Defense Science and Technology Strategy. This diverse array spans from biotechnology and microelectronics to hypersonics and renewable energy storage. The underlying message? Without cutting-edge manufacturing, these technologies remain mere concepts. As Wax succinctly put it, “if you cannot make it, you cannot have it.”
Among the manufacturing techniques in focus, additive manufacturing (or 3D printing) stands out. It’s not just about creating objects; it’s about revolutionizing the industrial base. The realms this technology touches upon include space technology, renewable energy, microelectronics, and more. By enabling affordable production of these innovative tools and systems, 3D printing serves as a bridge between conception and realization.
The synergy between the public and private sectors is paramount to bringing these manufacturing advancements to fruition. Through initiatives like America Makes, launched by the DOD in 2012, a confluence of industry experts, academicians, and government representatives work together. The collective aim? Accelerate the adoption of transformative manufacturing techniques in defense and boost the U.S.’s global manufacturing competitiveness.
Since its establishment, America Makes has steered 58 projects under the DOD banner, focusing on enhancing mission-critical systems and refining military supply chains and processes. Wax celebrates the success of this partnership, emphasizing its role as a cornerstone in the strategic deployment of additive manufacturing across the defense sector.
The journey of the past decade underscores the significance of manufacturing tech in defense strategies. As the boundaries of what’s possible expand, the interplay of technology and defense will undoubtedly continue to be a defining narrative for the years ahead.
