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Team 02

Team Members

Faculty Advisor

Nicholas Ganesh
Gianna Uba
Layal Hammad
Xueyang Zhang

Craig Calvert, Rajiv Naik

Sponsor

PepsiCo Frito-Lay

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Design and Implementation of A Food-Safe Solution to Prevent Chip Accumulation on Disabled Weighers by at Least 90%

This project focuses on the Design and Implementation of a food-safe diverter to improve operational efficiency and product quality in the chip packaging lines utilizing multi-head weighers. In these systems, radial feeders distribute chips into multiple weighing hoppers where product portions are measured before packaging. When a radial feeder is disabled for maintenance, chips continue to flow into the inactive feeder, leading to product accumulation, stale chips, and restricted product flow, reducing overall line efficiency. These disruptions also create food quality concerns and require operators to manually clear product buildup instead of managing other production tasks. The objective of this project is to design and implement a food-safe mechanical solution that prevents chip accumulation. The proposed solution is a Zone-1 compliant stainless-steel diverter that attaches to the top of a radial feeder. Once installed, the diverter redirects product flow away from the inactive hopper and into surrounding operating feeders, allowing continuous product flow. Engineering and operational constraints include FDA food safety regulations and limited access to detailed machine dimensions. Additionally, the design must be able to withstand Frito-Lay sanitization processes and resist corrosion. The component must also not interfere with the vibratory motion of the system. The project involves concept development, CAD modeling, prototyping, and testing to ensure compatibility with the packaging environment. The final deliverables include a stainless-steel pilot diverter prototype and documentation outlining installation and operating procedures. Successful implementation of the solution is expected to reduce chip accumulation on the disabled feeder by at least 90%. The design also has the potential to be scaled across all Frito-Lay North America sites, providing significant operational and financial benefits for the company.