Helping B‘laster’s Multiple Assembly Line Components Talk to Each Other

B’laster Holdings LLC, a leading producer of penetrating oils and specialty spray products, recently faced the daunting task of expanding their production capabilities inside its huge Medina, Ohio assembly plant.

The company sought to add an additional production line to accommodate various product types, necessitating a complex and rapid installation of advanced automation equipment. To do that, B’laster called on APEC Engineering and Harrington Electric Co. to ensure the project was completed swiftly and safely.

The new assembly line covered nearly 12,000 square feet and consisted of a zig-zagging conveyor system with roughly twelve primary assembly stations. These stations are responsible for different stages of production, from inserting marbles into cans to attaching straws to the sides. The intricate system required a cohesive and coordinated effort to integrate the equipment into a seamless high-speed operation.

Harrington’s role was pivotal in providing power and input/output (I/O) wiring from the floor’s programmable logic controller (PLC) cabinet to each station. This ensured that all components could effectively communicate with each other, creating a unified assembly system.

And as the assembly process involved a number of stations containing flammable aerosols, special approaches to electrical installations were required to adhere to strict safety guidelines and standards. Explosion-proof pathways, boxes, and disconnects were necessary, with threaded, rigid conduit installed meticulously to prevent any risk of vapor travel.

Harrington’s team, led by vice president of electrical construction, Jerry Strand, ensured that all assembly line components met these rigorous safety requirements, using a compound-filled seal-off method for the conduit to secure the pathways.

The project kicked off in May 2024 with a tight deadline, aiming for a mid-August completion to allow the line to go live by the third week of August. Despite a traditional installation timeline of six months, the project was fast-tracked by B’laster to be completed within three to four months. This demanding schedule required the coordination of a six-person team of Harrington employees, who often put in ten-hour days to stay on schedule.

The installation involved laying over a mile and a half of pipe and an equivalent amount of cabling. Additionally, the team designed the raceways and pathways virtually on the fly, adapting to the unique requirements of the automated line.

“The team had to be very flexible with design and execution, especially when installing the supports, control cabinets, and enclosures,” Jerry Strand noted, adding that longtime design partner, APEC Engineering, played a crucial role in overseeing the project and ensuring that all designs were practical and efficient.

Outside Jurisdiction Results In Forging New Worker Relationships

An interesting aspect of the project involved some slight geographic and logistical challenges. Medina County, where the B’laster facility is located, is outside of Harrington Electric’s usual jurisdiction. This necessitated pulling resources from local unions in Akron and surrounding Summit County (through a collective bargaining agreement), and forming new relationships with electrical professionals who were recruited to join the project team.

The success of the project can be attributed to the dedicated team led by Rob Lee, with significant contributions from Ron Thacker and Frank Madancic. The collaboration between Harrington Electrical and APEC Engineering, along with other local construction resources, was instrumental in meeting and overcoming the project’s challenges.

The fast-track nature of the project highlighted the importance of flexibility, efficient communication, and solid partnerships, and exemplified the importance of having a capable and adaptable team to navigate the intricacies of large-scale installations.

The new production line at B’laster is a testament to what can be achieved with a skilled and coordinated effort. Harrington Electric’s ability to deliver high-quality work under tight deadlines ensured that the new production line at B’laster was fully operational on time, meeting the company’s production goals and ensuring success as the line powers up to fill customer demand.