Coffee drinkers in the United States and Europe combine to brew in the neighborhood of 150 million Keurig coffee pods daily. In many cases, Haskell created the systems that control the manufacturing lines that keep all those folks caffeinated.

Keurig Dr. Pepper (KDP), maker of the uber-popular K-Cups, partners with Virginia-based Allfirst, LLC, for the mechanical design and construction of its lines. With no Automation and Project Controls team of its own, Allfirst relies on Haskell’s experts as a preferred controls provider.

Recently, Haskell has executed numerous projects through this partnership, including packaging line controls for lines in Essex, Vermont; Knoxville, Tennessee; and Sumner, Washington. The primary scope typically involves electrical cabinet design, device layout consultation, and PLC/HMI (Programmable Logic Controller/Human-Machine Interface) programming for the K-Cup conveyor system that transports newly created cups from the filler to the cart or case-packing systems.

The typical cup conveyor systems are significantly smaller than many Haskell projects, but they come with unique complexities. The systems typically have from four to 10 motors driving conveyors to a variety of packing systems. A hopper system with a rotary sortation bowl provides accumulation to buffer downtimes.

Controlling the line optimally means getting the most out of these sorter bowls to keep the cartoners running as fast as possible. A series of diverters balances flow from one bowl to multiple infeed lanes to a typical packer. Ensuring the product flow is balanced and switching time and frequency are minimized keeps the packers running smoothly at their highest rate to pull down the accumulation hoppers.

The Haskell team’s adaptability and flexibility are the keys to the successful partnership with Allfirst.

Projects generally include a large amount of contingency funding because the scopes of work typically evolve throughout the execution. Haskell often procures last-minute electrical components, takes on additional controls programming scope and works through problems with vendors in the field.

Allfirst relies on Haskell’s teams to identify gaps in their plans and create cost-effective solutions that meet the necessary schedule.

“Since much of the equipment being installed is reused machines from across the KDP network, you never know what you will find on a project,” Automation Integration Manager Craig George said. “For example, we’ve refurbished used glue pots that were no longer operational with the original wiring, generated as-built drawings for old panels from Italy, and pulled together last-minute PDPs (Principal Display Panels).”

Appreciative of Haskell’s customer service-oriented approach, Allfirst has leveraged the Haskell team on nearly two dozen lines in the KDP network over the past two years, and work is ongoing.

Haskell’s subject matter experts consistently maintain a holistic and innovative approach to problem-solving, which means they regularly participate in solutions-focused discussions across disciplines and industries. Contact our team to leverage that thought leadership on your next project.