As the authorised Australian distributor for Regal Rexnord’s System Plast® conveyor solutions, Dotmar Engineering Plastics provides customers with access to the innovative Modsort® Diverter Station range for advanced material handling and automation applications. Designed for high-speed secondary packaging and end-of-line operations, ModSort systems enable the smooth sorting of sealed cartons, pouches, trays and cases without interrupting product flow. Backed by Dotmar’s local engineering expertise, technical support and nationwide service network, customers can integrate Regal Rexnord’s proven sorting technology into food and beverage, logistics and manufacturing facilities with confidence.
Where it fits in a food packaging line
The ModSort unit sits on the conveyor after products have been packaged and inspected, directing them to the correct downstream destination.
Example applications
1. Sorting products by destination
A snack manufacturer producing multiple flavours may use a ModSort station to direct:
- Barbecue-flavoured cartons to one palletising cell
- Salted cartons to another
- Promotional packs to a separate shipping lane
The decision is made automatically based on barcode or production data.
2. Rejecting failed products
If an inline checkweigher or vision system detects an underweight or incorrectly labelled package, the ModSort station can gently divert it to a rework conveyor while allowing compliant products to continue uninterrupted.
3. Feeding multiple palletisers
On high-speed lines, a single packaging machine may produce more cases than one palletiser can handle. A ModSort diverter distributes cartons between two or more palletising cells to balance throughput.
4. Warehouse and distribution routing
Finished cases can be diverted toward different loading docks, cold storage areas, or automated storage systems depending on customer orders or shipping schedules.
Why it is well suited to food packaging
The system offers several benefits that align with food manufacturing requirements:
- Gentle handling: Reduces the risk of damaging lightweight cartons, flexible pouches, or delicate packaged products.
- Continuous flow: Diverts products without stopping the conveyor, maintaining high line speeds.
- Reduced maintenance: Eliminates many of the pneumatic cylinders and mechanical pushers used in conventional diverters.
- Modular integration: Can be incorporated into existing conveyor layouts with minimal disruption.
- Compatibility with automation: Interfaces with PLCs, barcode scanners, vision systems, and warehouse management software to make real-time routing decisions.
For example, a frozen meal facility could package meals into cartons, pass them through quality inspection, and then use a ModSort diverter to automatically separate products destined for domestic supermarkets, export orders, or quality-hold storage—all without slowing the production line.
