Comprehensive Guide to Dairy Case Stackers: Exploring Types, Innovations, and Key Differences. What's the difference between case stackers?

In modern dairies, case stackers play a crucial role in streamlining operations. Despite a general similarity in their core function, they exhibit key differences, particularly when integrated into dairy chains, commonly referred to as drag chains (both 3500 chain and 3498 chain).

Basic Operation of Dairy Case Stackers

• Functionality: Typically, either a single or double dairy case enters the stacker. Some models, like those available at Knight Industrial, can handle triple cases.
• Process: The stacker halts additional cases from entering while it lifts the current case(s) onto a case rest. Then, it allows new cases in for subsequent lifting. This cycle usually builds stacks up to five or six cases high.
• Key Feature: Nesting rings in the stackers ensure that the cases stay "nested" or securely stacked.

The Core Types of Case Stackers and Their Distinct Features

1. Hydraulic Case Stackers:
   • Operation: Utilize hydraulic force with a hydraulic cylinder for lifting.
   • Additional Functions: May include other hydraulic components for infeed stopping and case resting.
2. Pneumatic Case Stackers:
   • Operation: Employ pneumatic force with a pneumatic cylinder.
   • Other Mechanisms: Generally, use air force for most or all other mechanical functions.
3. Electric Case Stackers:
   • Operation: Lift cases using an electric gearmotor.
   • Note: Distinct from hydraulic over electric and pneumatic over electric stackers, which use electric power (typically 24 volts) to operate solenoids that control hydraulic or pneumatic lifting.
4. Servo Stackers (Knight Industrial):
   • Type: A variation of electric stackers, utilizing a servo motor for lifting cases and stacks on the dairy conveyor.

Knight Industrial's Influence in the Dairy Case Stacker Market

• Historical Context: Cannon Equipment, a leading manufacturer until mid-2020, exited the dairy industry. In 2021, Knight Industrial acquired Cannon's engineering, designs, parts, and service.
• Knight Industrial's Enhancements:
  • Preservation: Maintained key wear components like cam rollers, bearings, and cylinders.
  • Advancements: Introduced improvements in controls, electrical schematics, enclosure components, wiring, and safety guarding.

Identifying the Primary Differences Over Dairy Conveyors

The primary differences between these stackers in a dairy environment, particularly over dairy conveyors, lie in their lifting mechanisms (hydraulic, pneumatic, electric, or servo) and the specific enhancements and features they offer. These differences impact factors such as operational speed, stack height capability, energy efficiency, and maintenance requirements.

Conclusion

While dairy case stackers share a basic operational principle, their distinctions in mechanics and design enhancements by companies like Knight Industrial underscore the diversity in this equipment category. Understanding these variations is crucial for dairy processors to select the most suitable stacker for their operations, ensuring efficiency and compatibility with their existing dairy chain systems, including the 3500 and 3498 drag chains.

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FAQs about Dairy Case Stackers

1. What is the basic operation of dairy case stackers in today’s dairies?
   • Dairy case stackers, integral to dairy chains or drag chains (including both 3500 chain and 3498 chain), typically operate by allowing a single or double dairy case to enter the stacker. A mechanism prevents additional cases from entering while the stacker lifts the case(s) onto a case rest. This process can be repeated to stack cases typically up to five or six high, with nesting rings keeping the cases securely nested together.
2. How does a hydraulic case stacker function and what are its additional features?
   • Hydraulic case stackers lift dairy cases using hydraulic force from a hydraulic cylinder. They may also include other hydraulic functions like infeed stops and case rests, enhancing their functionality in dairy processing.
3. What distinguishes a pneumatic case stacker and its operations?
   • Pneumatic case stackers operate using pneumatic force from a pneumatic cylinder. These stackers primarily utilize air force for most, if not all, of their mechanical functions, offering a distinct mode of operation.
4. Can you explain what an electric case stacker is?
   • Electric case stackers lift dairy cases using an electric gearmotor and typically employ air force for most other mechanical functions. It’s important not to confuse them with hydraulic over electric stackers or pneumatic over electric stackers, which use electric power (typically 24 volts) to operate a solenoid for hydraulic or pneumatic lifting.
5. What is a servo stacker, and how does it differ from other electric stackers?
   • Servo stackers, a unique innovation by Knight Industrial, use a servo motor to lift dairy cases and stacks on the dairy conveyor. This is a specialized type of electric stacker offering precise control and efficiency in lifting operations.
6. What historical role did Cannon Equipment play in dairy case stacker manufacturing?
   • From the 1970s until early 2020, Cannon Equipment (also known as Cannon Machinery) was a leading manufacturer of dairy case stackers. They exited the dairy industry in mid-2020, marking a significant change in the industry landscape.
7. How has Knight Industrial improved dairy case stackers since acquiring Cannon Equipment’s designs?
   • Knight Industrial purchased Cannon Equipment's engineering, designs, parts, and service in 2021. They have made several improvements to the dairy case stackers, including upgraded controls, electrical schematics, enclosure components, wiring, and guarding, while retaining key wear components like cam rollers, bearings, and cylinders. These enhancements have solidified Knight Industrial’s position as a producer of top-quality dairy case stackers.

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