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Hytrol Conveyor Company’s Second IntelliFinishing System

For many manufacturers of equipment, finishing system efficiency and flexibility are paramount. For Hytrol Conveyor Company, a leader in innovative conveyor solutions since 1947, these qualities are non-negotiable. When Hytrol first integrated an IntelliFinishing system at its headquarters in Jonesboro, Arkansas, the results were impressive. (Read about the first Hytrol IntelliFinishing install here.) Fast forward, and Hytrol’s growth in output and desire to diversify their locations created a need for a second IntelliFinishing system at their new facility in Fort Smith, Arkansas. This time, however, they were looking for something even faster, able to handle larger parts, and even more adaptable and flexible than their first system.

A Brief Overview of Hytrol

Founded in 1947, Hytrol Conveyor Company has grown to become a powerhouse in the material handling industry. Specializing in designing and manufacturing advanced conveyor systems, Hytrol serves a variety of sectors, including manufacturing, distribution, and supply chain. Headquartered in Jonesboro, Arkansas, the company has expanded significantly, establishing a reputation for innovative solutions and a strong commitment to community involvement.

The Journey with IntelliFinishing

Hytrol’s first IntelliFinishing system was installed in 2015 at their headquarters in Jonesboro Arkansas. The system’s flexibility, durability, and finish quality led them to choose IntelliFinishing once again in 2020 for their Fort Smith location. This decision was driven by their satisfaction with the first system plus the need for a faster system capable of handling larger parts and offering enhanced recipe flexibility.

Why IntelliFinishing?

The unique attributes of IntelliFinishing systems set them apart. Key features include the spinning tube conveyor that ensures a cleaner operation by eliminating common contamination issues seen in traditional chain systems. Reliability and reduced maintenance were crucial factors for Hytrol, as was the creative layout configuration that IntelliFinishing systems provide. The control system’s integration capabilities, which unite all process equipment onto an easy-to-use HMI software, were also a significant draw. This system allows for real-time tracking and unlimited recipe adjustments, ensuring optimal finish quality and overall system efficiency.

Flexibility: A Crucial Component

Flexibility is vital for Hytrol’s finishing system, which handles a wide range of products from small brackets to large, heavy assemblies. The new system’s design incorporates various load and unload areas, facilitating the handling of larger parts without obstruction. The Fort Smith system can process up to 75 twelve-foot carriers per hour, compared to the approximately 50 ten-foot carriers per hour at Jonesboro, representing a significant increase in throughput. Additionally, the system has an extra recirculating loop just outside the e-room. On high-speed systems like this, where color changes are frequent, sometimes a carrier needing a new color arrives at the e-room, just before the booth, but the booth isn’t ready or other booths in the e-room are backed up a bit, blocking the carrier and bottlenecking all the booths in the e-room. Hytrol’s system has four booth options.

The recirculating loops allow carriers of parts to divert away from the e-room and go into a holding pattern until the desired booth is ready for it. Thus, the circulation loop helps manage workflow and reduce booth bottlenecks, without restricting the loading of new color products earlier in the system. Products that require a booth color change can be loaded at will and operational scheduling of colors is minimized, thus reducing manpower needs.

Comparing to Traditional Systems

Hytrol’s previous Power and Free based paint systems were prone to frequent downtimes, often up to 15% of the time. In contrast, the IntelliFinishing systems have demonstrated remarkable up-time and minimal maintenance needs. Due to the independent movement of each carrier through the system, minor carrier and track maintenance can often be completed quickly but without slowing or even interfering with down-stream carriers. After maintenance carriers often catch up to previously processed carriers due to variable speed controls. This independent carrier operation and variable speed underscores the system's resilience, reliability, and ability to make the desired throughput rate of carriers per hour.

A Resounding Success

Given the success of their first IntelliFinishing system, Hytrol did not hesitate to install their second faster, larger, and more flexible IntelliFinishing system. The recipe control of both systems, plus the lack of contamination issues common with chain systems have allowed Hytrol to improve their paint finish quality significantly, boosting customer satisfaction and enabling them to cater to large material handling clients like Amazon more effectively.

Testament to IntelliFinishing’s Value

Hytrol’s Fort Smith project was a testament to IntelliFinishing’s commitment to excellence. Despite the challenges, the system was operational on time and within budget. The final approval for the system was given in January of 2020 and the system was operational by August of 2020! Three years later (in 2023), the addition of a Hytrol floor roller conveyor to feed the finishing system with parts from fabrication to the paint line, further streamlined the production process, enhancing efficiency and safety.

Looking Ahead

As Hytrol continues to expand, their partnership with IntelliFinishing remains a cornerstone of their operational strategy. The adaptability and reliability of their IntelliFinishing systems make a trusted part of Hytrol’s family and future growth plans, ensuring Hytrol stays at the forefront of the material handling industry.