When Amcor needed to modernize their injection molding lines, they didn’t just need hardware—they needed custom conveyor solutions for plastics that could handle tight spaces and frequent mold changes.
The Company
Amcor is a global manufacturer of rigid plastic packaging, with advanced injection molding operations that produce high-performance bottles, containers, and components for challenging food, beverage, and healthcare applications.
The Challenge
The plant needed to replace legacy conveyors that were inefficient due to downtime and poor product containment – parts fell onto the floor, requiring operator cleanup and causing product waste. In addition, the operation has daily mold changes, and the legacy conveyors could not easily change with the mold changeout resulting in downtimes. As a world-class manufacturing operation, Amcor faced growing material handling challenges, specifically regarding space constraints and inefficient part transfer.
The Solution
Robert Greenfield, Automation Technical Set Up Lead, found Dynamic Conveyor while searching for a more reliable plastics industry conveyor. He was immediately attracted to the simple design and modular features. Scott Kreilein, Injection Molding Automation Engineer, saw the conveyor solutions firsthand at Pack Expo in Chicago.
The Dynamic Conveyor design process gave the Amcor team direct access to collaborate with experienced Applications Engineers to develop the custom conveyor solutions to solve their pains. The Amcor team comments on the uniqueness of the collaboration and quality of the approval drawings delivered at the time of the proposal.
DynaCon modular conveyors and DynaPro low profile conveyors replaced old equipment, solving critical part containment issues, reducing operator cleanup time, and allowing for conveyor mobility for changeovers. A quality and effective belt conveyor system with flights/cleats and sidewalls were identified as key components to containing parts. The highly flexible modular designs that included casters would allow for quick and easy daily mold change overs.
The Results
Amcor and Dynamic Conveyor worked together to engineer reliable modular conveyor systems that enable sub-30-minute changeovers minimizing downtime and contributing to increased throughput. Highly flexible design allows for quick reconfigurations from flat → incline → Z configurations in brief time and minimizing space constraints.
The conveyor systems have been running for several years and there has been no downtime due to maintenance. In the few scenarios where a belt has been damaged by operational mishaps, section belt repairs were less than 30 minutes preventing costly downtime. Amcor stocks motors and gearboxes to ensure any major failure can be fixed in under 60 minutes, however, hasn’t had to use these parts after years of conveyors in operation.
Seamless transfer between conveyors provides superior part containment preventing parts from falling. Amcor floor operators have a strong preference for DynaCon set ups since they make their jobs easier, because parts drop directly into boxes, cutting out part floor cleanup and product waste. Amcor also reports increased operator safety with no pinch points.
“The support from Dynamic Conveyor is top-notch” says Scott Kreilein. “From Engineering collaboration to Sales and Technical Support, the experience working with Dynamic Conveyor is excellent. We had tight deadlines and Dynamic Conveyor delivered” Scott continued.
We’ve been in business 35 years solving challenges in the plastics, general manufacturing and food processing industries. Contact us for your custom conveyor solutions.
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