Trade shows are where ideas become reality.
At PACK EXPO International 2024, a manufacturer stopped by our booth with a challenging parts feeding application. They needed a reliable way to orient and feed stoppers at a consistent rate—and they needed a solution that would seamlessly integrate with robotic automation.
That conversation on the show floor became the spark for a custom vibratory bowl feeder system that’s now running on their production line. Here’s how it happened.
The Challenge: Precision Feeding for Robotic Integration
The customer’s requirements were specific and demanding. They needed to feed stopper parts efficiently while maintaining precise orientation: diameter-to-diameter at random, axis vertical, large diameter up, hanging from a single horizontal discharge.
But orientation was just the beginning. The system also needed to:
- Include a spring detent dead nest with a part-present sensor for reliable robotic pick
- Achieve a consistent throughput of 40 parts per minute
- Feature safeguards like high-level photocell shut-off and low-level hopper sensors
- Integrate seamlessly with their existing robotic automation
It was the kind of application that required more than an off-the-shelf solution. It needed a custom approach designed specifically for their parts and process.
The Spark: A Live Demo That Made the Connection
While visiting our booth at PACK EXPO, the customer saw our 12″ clockwise 304 stainless steel vibratory feeder running live on the show floor. Watching the system in action, they immediately recognized it could be the foundation of their solution.
That’s the power of live demonstrations. Seeing equipment run with actual parts helps customers visualize how a system might work in their own facility. What started as a booth conversation quickly turned into a detailed discussion about their specific application, requirements, and timeline.
By the end of the show, we had a clear understanding of what they needed, and they had confidence we could deliver it.
The Build: Engineering a Custom Solution
Back at our facility in Knightstown, our engineering team got to work translating that trade show conversation into detailed drawings and specifications. The design phase involved close collaboration with the customer to ensure every element would meet their exact requirements.
The system centered around a 12″ clockwise vibratory feeder with a tool steel track and inline drive, paired with a 304 stainless steel storage hopper. But the real engineering work was in the details:
- Designing the orientation system specifically for stopper geometry
- Integrating the spring detent dead nest to create an isolated, consistent pick point
- Installing part-present sensors to signal the robot when parts were ready
- Adding high-level and low-level sensors for automated hopper monitoring
- Configuring the system to maintain the 40 PPM feed rate consistently
As the system took shape in our shop, we kept the customer informed with progress updates, photos, and opportunities for feedback. This collaborative approach ensured the final system would integrate smoothly into their operation.
The Solution: Delivering Performance and Reliability
The finished system delivered on every requirement:
12″ Clockwise Vibratory Feeder with Tool Steel Track
Designed specifically for stopper parts and built to handle the demands of continuous production with an inline drive for consistent performance.
304 Stainless Steel Storage Hopper with Level Monitoring
The integrated low-level sensor alerts operators before the feeder runs empty, minimizing downtime and maintaining consistent flow to downstream processes.
Spring Detent Dead Nest with Part-Present Sensor
Creates a reliable, isolated pick point that works seamlessly with robotic automation. The part-present sensor signals exactly when a part is positioned and ready for pick, eliminating guesswork and failed picks.
High-Level Photocell Shut-Off
Automatically pauses the feeder when parts reach capacity, preventing jams and protecting both the system and the parts from damage.
The Results: Efficiency, Reliability, and Throughput
The system now runs consistently on the customer’s production line, achieving the target 40 parts per minute feed rate. The spring detent dead nest provides a dependable handoff point for the robot, and the automated level monitoring keeps the system running with minimal operator intervention.
But beyond the numbers, the real result is reliability. The customer no longer worries about inconsistent part orientation, missed picks, or unexpected downtime. The system does exactly what it was designed to do, shift after shift.
What Starts at the Trade Show Doesn’t Stay at the Trade Show
Projects like this start with a conversation. Whether it’s at a trade show booth, over the phone, or during a facility visit, the best solutions begin when we understand your specific challenge.
If you’re attending The ASSEMBLY Show, stop by Booth #1505 at the Donald E. Stephens Convention Center, October 21–23, to see our systems running live and explore how we can build a custom solution for your application. And if you can’t make it to the show, we’re always ready to discuss your parts feeding challenges and explore what’s possible.
Ready to solve your parts feeding challenge?
Contact Hoosier Feeder today to discuss how a custom feeding solution can improve efficiency, reduce downtime, and integrate seamlessly with your automation. From initial concept to final installation, our team is here to turn conversations into solutions that deliver results.