In episode 30 of The Downtime, a weekly manufacturing podcast from WTWH Media, co-host Sarah Wynn talks with Bill Reese, general manager of accumulation and senior director of engineering at Columbus McKinnon. The discussion covers Garvey’s new aluminum Bi-Flo accumulation table, including its energy-efficient design and how cross-brand collaboration helped develop the system to reach new markets where washdowns aren’t required.
Wynn also highlights Packaging OEM’s latest research report, which details how conveyors have advanced from simple product transport to the backbone of control and communication on the plant floor. Click here to download.
Co-host Sheri Kasprzak discusses a recent Control Engineering story about Beckhoff Automation’s TwinCAT 3 Machine Learning Creator, a web-based tool that allows engineers to build and use artificial intelligence (AI) models without specialized data-science knowledge.
Collaboration across Columbus McKinnon
Garvey announced the aluminum Bi-Flo accumulation table in October 2025. Designed to keep products moving smoothly on packaging lines by recirculating items in a controlled loop, the system was engineered through collaboration within the Columbus McKinnon Corporation’s conveyance group.
“We teamed with Dorner to develop the aluminum Bi-Flo and touch markets that might be more industrial, where stainless steel isn’t required,” said Reese, adding that the collaboration helped Garvey reach new customers.
Because washdowns are not required, the aluminum Bi-Flo can be deployed in markets such as industrial, consumer goods, machine parts, and nutraceuticals.
Energy-efficient motor design
The aluminum Bi-Flo uses three modular chain sets running in opposite directions to accumulate, buffer, or feed product while maintaining continuous flow in a compact footprint.
Reese said the accumulation table replaces the traditional two- or three-motor setup with a single, slightly larger motor that drives all three chains while providing sustainability benefits.
RESEARCH | Energy Efficiency in Packaging Machines: A Growing Priority
“It tends to be more energy-efficient because the single motor can run in its most efficient range,” he said. “It’s less complicated integration-wise. You only need one variable frequency drive (VFD) instead of three, and maintenance is simpler with fewer moving parts.”
Real-world deployment
While the system was only recently announced, it has already been deployed on a nutraceutical packaging line to handle sealed pill bottles.
Reese added that the system has shown efficiency gains for the customer. “They wanted to buffer their labeling system during changeovers,” he said. “The aluminum Bi-Flo kept everything running, improving throughput and freeing up labor.”
Listen to the full interview to hear more from Reese about Garvey’s aluminum Bi-Flo and how collaboration across Columbus McKinnon is reshaping accumulation design.
Episode 30: Material Girls | Show notes & time stamps
00:17 – The co-hosts begin the show
00:25 – Wynn notes that this episode will focus on material handling and smart conveyance
03:13 – Kasprzak covers a recent Control Engineering story about Beckhoff’s TwinCAT 3 Machine Learning Creator
04:15 – Wynn discusses Packaging OEM’s research report on smart conveyors and material handling
05:05 – Wynn outlines Columbus McKinnon’s conveyance brands and introduces this week’s guest: Bill Reese, general manager of accumulation, senior director of engineering at Columbus McKinnon conveyance
05:55 – Interview with Bill Reese begins
06:07 – Reese introduces himself and explains Columbus McKinnon’s conveyance portfolio, including Garvey, Dorner, and montratec
06:45 – Reese introduces Garvey’s new aluminum Bi-Flo accumulation table and details the collaboration with Dorner
07:55 – Reese notes the cost savings from switching to aluminum from stainless steel construction
08:30 – Wynn asks how the Bi-Flo’s single motor design impacts energy efficiency
10:55 – Reese describes the configurations of the aluminum Bi-Flo accumulation table and how they help manufacturers optimize production lines
13:44 – Reese offers tips for multi-line setups and layout challenges
16:49 – Reese explains how the aluminum Bi-Flo has been integrated into a nutraceutical line
19:30 – Reese expresses excitement to work with a new segment of customers, interview wraps up
20:15 – The co-hosts mention that there will be no new episode of The Downtime on Thanksgiving and encourage listeners to listen to previous episodes
21:01 – Convey or Slay game time segment begins with the co-hosts debating Thanksgiving dishes
25:28 – The co-hosts wrap up the show
About The Downtime podcast and co-hosts
The Downtime is a weekly manufacturing podcast from WTWH Media that features insights from its automation and controls publications. It’s co-hosted by Wynn, who serves as the senior editor (digital) for Packaging OEM, and Kasprzak, who is the executive editor for Plant Engineering, Control Engineering, and Consulting-Specifying Engineer.
The podcast is available weekly on YouTube, SoundCloud, and Spotify.
Check out The Downtime’s recent episodes
Episode 25: Inside WTWH Media’s “Can’t Stop, Won’t Stop” B2B content strategy
Episode 26: Unpacking Pack Expo, a journalist’s perspective
Episode 27: Conveying candy and material handling trends with Flex-Line Automation
Episode 28: How Fallas Automation engineers flexible end-of-line systems
Episode 29: Fanuc’s robotic solutions for warehousing and material handling automation
