The challenge
Zeffer, a multi-beverage company based in Hawke's Bay, New Zealand, faced significant challenges in the wake of Cyclone Gabrielle in February 2023. The cyclone caused extensive damage to their production site, requiring a complete redesign of their packaging line and a new packaging shed.
This presented a tricky logistical hurdle: transporting product from the old filling room, through a wall, and into the new packaging shed. Zeffer needed a customised conveyor system that could seamlessly integrate into their redesigned production process and accommodate future growth.
They sought a reliable partner who could understand their specific needs, provide a bespoke solution and deliver a high-quality, efficient system.
The solution
Dyno Conveyors stepped in with a practical approach that tackled each aspect of Zeffer's challenge.
At the core of the design are two key conveyor sections that improved Zeffer's product flow. The first is a horseshoe-shaped conveyor system made from stainless steel 304. This material was chosen for its durability in beverage handling environments. This system features side-flexing slat chains that efficiently guide products from the pasteuriser through a 180-degree bend and into the air dry section, with stainless steel guide rails ensuring smooth product flow around the curves.
Dyno’s systems are well-suited to handle the transition between different packaging stages. After air drying and accumulation, products move to the Spartan case packing machine. Here, Dyno's engineering expertise shines through in the smooth product handling from case packing to the taping section. The S20 Slimline belt conveyor, with its specialised slippery-top belt, ensures consistent product flow through the packaging phase.
Dyno also installed a custom pneumatic chain transfer unit in the final stretch, through quality assurance and into the palletisation area. This clever bit of engineering, part of the Tranzband powered roller conveyor system, ensures boxes stand perfectly upright as they move from the taper to final packaging. The entire system maintains a consistent working height of around 900mm, with micro-adjustable stands allowing for perfect levelling across the existing facility's layout.
The result
The new system has transformed Zeffer's operations, giving them the speed and reliability they needed to bounce back stronger after the cyclone:
Nearly doubled production speed through enhanced automation
Reduced manual handling requirements, improving workplace safety
Maintained consistent product quality through precision handling
Three-phase drives throughout ensure reliable operation even during peak periods
Stainless steel construction in critical areas ensures long-term durability
Modular design allows for future expansion or modifications
This project shows how Dyno Conveyors combines practical design with quality manufacturing to solve real business challenges. By listening carefully to what Zeffer needed and delivering a system that worked for their specific situation, Dyno helped turning the tragedy of the natural disaster that hit our country into an opportunity for improvement.
Jack Anderson, Head of Beverage at Zeffer Brewing, completed the installation in December 2023 and was thoroughly impressed: “We couldn't have done it without Dyno. I am really happy with the design and the way it came out. Dyno were very receptive to any changes I wanted to make and had good recommendations. They're competitively priced with good customer service. If we needed to change our packaging line again, I'd definitely use Dyno.”
