FOOD & DRINK PROCESSING & PACKAGING
Mitsubishi Electric The Art Of Slicing
TCL Packaging
Invests In New Solvent-Free Laminator March / April Issue 07 2016
SOLUTIONS FOR THE SMART FOOD FACTORY PLUS... Measuring pH in a food-safe environment
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1.08.2015
Innovative Vacuum Solutions for Packaging and Food Processing
Vacuum technology has become a crucial element for many tasks in the food packaging and food processing industry. Many years of experience in vacuum engineering and the latest developments in pump technology gives the oil-sealed rotary vane SOGEVAC range the capability to adapt to the requirements of the industry. The comprehensive range of pumping speeds from 10 to 1200m2/h allows every customer to select the right pump for his application. The SOGEVAC range has the highest water vapour-handling capabilities on the market and PFPE variants for MAP with oxygen are also available. This product will convince you with its robustness, compact design and low noise emissions. Detailed information is available on: www.leybold-foodandpack.com.
Strong in performance and reliability! Oerlikon Leybold Vacuum UK LTD. Unit 9 Silverglade Business Park Leatherhead Road Chessington Surrey KT9 2QL United Kingdom T: +44 1372 737300 sales.vacuum.ln@oerlikon.com
Contents
Endoline Systems Rise To The Occasion For Olympic Artisan Baker - A baker and supplier of artisan breads has recently opened a £3 million state of the art factory on the back of their Olympic 2012 success and Endoline Machinery has helped them reach gold production standard with their fully automated turnkey packaging line – which now sees an output of around 1,000 cases per day.
TCL Packaging Invests In New Solvent-Free Laminator - “Not only is the new laminator helping clear our order backlog, its solvent-free application is ensuring we continue to exceed our environmental targets” concludes Langford.
42 Technology and Gabler develop gum manufacturing breakthrough with Mondelez International - 42 Technology has partnered with Gabler GmbH & Co. KG, one of the world’s leading providers of manufacturing process equipment, to help Mondelez International make a dramatic improvement in the efficiency of its chewing gum manufacturing process.
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M H Media Global Ltd. St Augustine’s Business Centre, 125 Canterbury Road, Westgate On Sea, Kent, CT8 8NL
Tel 01843 830249 l Fax: 08721 152240 l www.fdpp.co.uk
Endoline Systems Rise To The Occasion For Olympic Artisan Baker A baker and supplier of artisan breads has recently opened a £3 million state of the art factory on the back of their Olympic 2012 success and Endoline Machinery has helped them reach gold production standard with their fully automated turnkey packaging line – which now sees an output of around 1,000 cases per day. Speciality Breads produce over 100
of end of line system expert Endoline
Once frozen the loaves and rolls are
different types of handmade breads,
Machinery to install a state of the art high
immediately packed onto crates and
from focaccias to brioche and ciabattas,
speed packaging line.
transported to the packing station. At the
at their Margate based production plant.
start of the line a fully automatic Endoline Endoline, who design and manufacture all
case erector forms the Speciality Breads
After winning the bakery contract to
of their systems from their Bedfordshire
cases which are then fed down to a
supply bread and rolls to the Olympic
based factory, installed and integrated
Pattyn bag inserter machine, which has
team in 2012, demand for their produce
additional supplier equipment into the
been integrated into the line to insert a
has grown with annual sales increasing
fully automated packing line – at a speed
bag into each formed case.
by 30% over the last 3 years. As a direct
of 8 cases per minute.
result Speciality Breads has recently
The formed, and securely lined, cases
opened a second 3,000 square metre
Speciality Breads freshly bake a daily
are then transported via an inclined
site, just minutes away from the
supply of 20 different lines of artisan
automated conveyor system to four
original bakery which opened almost
breads which are immediately frozen
packing
20 years ago. Flying the flag for British
and packed to be distributed to the UK’s
operators take an empty box down from
Manufacturers and suppliers, including
leading bars, pubs, cafes, restaurants,
head height, pack the frozen unpackaged
only using Red Tractor* certified flour,
hotels and caterers via the many
product inside, before placing onto a
Speciality Breads employed the expertise
wholesalers they supply across the UK.
lower conveyor.
stations
where
manual
James Saywell, Endoline’s Southern
integrated an existing labeller and metal
Sales Manager, comments: “As the
detector into the end of the conveyor.
boxes running along the first conveyor
The
were empty and therefore light we
transported back to a storage freezer
*All foods carrying the Red
built this system on an incline to run at
to ensure they remain at an ambient
Tractor mark have been produced
head level for the packers to ensure it
temperature before being palletised and
was ergonomically friendly and also to
transported to customers.
are
then
immediately
make the packing process as swift as
,,
boxes
to British Farm Standard, which covers everything from
possible.” The second, lower conveyor
“A case can be formed filled, sealed and
environmental practices to food
line runs the filled boxes straight through
checked within 1 minute” explains James, “this ensures that the product remains at
hygiene, food safety and animal
to the Endoline case sealer to deliver a professionally sealed box.
Endoline
its frozen temperature so, while packing
project managed the entire line and
is efficient, it is done in a timely manner
welfare, all of which is checked via strict independent inspections.
to preserve quality.”
MD Peter Millen explains how the new facility is the final piece of the puzzle to ensure the company has everything it needs to continue to move forward: “With the UK foodservice sector as vibrant and diverse as it is and interest in our breads going through the roof, this new site was vital for us in order to keep up with demand and continue to grow. Our new facility and the automated Endoline packing line give us the high-spec packaging plant I envisaged and it offers Speciality Breads scope for future growth.”
Product News Control & Automation
Increased capacity palletising robots New RGC and RGS proportional controller series won’t leave you in the cold Capable of operating 2050 cycles per hour with a 130kg payload is the claim of Kawasaki Robotics for its new CP range of palletising robots. Three new models make up the CP range, offering maximum payloads of 180, Carlo Gavazzi has introduced the compact and easy to install RGC1P and RGS1P series of single-phase proportional controllers to its popular solid 300 and 500kg. state relay range for power control applications. High throughput, a wide working range and ease of programming In many applications, are attributes that position the the output signal range competitively in the market. from measuring and By reducing robot weight by up to monitoring devices is 38% over the range it replaces, and an 3/3 analogue signal that SHRINK PACK ELEVATOR METTLER TOLEDO Introduces New KUKAfor LBR IIWA ROBOT OPTIMIZES enhancing the drive mechanism needs to be converted the arm’s rotation (joint 1), payload Checkout Scale SMT LINES FOR THE ELECTRONICS intoLAYOUT a digital ISSUES signal toRESOLVED capacities have been increased in line switch a ‘standard’ INDUSTRY A fast-growing METTLER TOLEDO is pleased to introduce solid state relay. beer This bottler was faced with a with overall performance.
the Ariva-H, its newest advancement in canreal bechallenge costly, when uses conducting a complete Two applications illustrate ways of additional space inofthe modernisation their filling and packaging weighing at the checkout. TheHensman, Ariva-H Kawasaki implementing Ian Robotics’ human-robot collaboration panel and takes longer salesscale and with marketing manager points About a dozen combines a fast and reliable a to area. install. Using Carlo of the shrink packing At ASM, the LBR iiwa interacts with the out thatchoice the new lines needed popular scanner of the retailer’s into arm offers the Gavazzi’s space elevation saving in some stages humanby operator without a safety fence – in optimal flexibility demanded RGbetween proportional controllers the analogue input signal one will be automatically the first and second shrink wrapping system that can be integrated into the manufacturers and food processors today: “The CPstationary Range robots rank as best in both the mobile and applications. calculated deliver stations, the appropriate output power. checkout lane. and the and palletizing but there was no class when running the standard industry takt test for large robots; 400 mm up,
At the ASM in-house Technology Show 2015
available. control series is equipped withMETTLER 2000 mm horizontal and 400mm down. Having the ability to increase palletising Thespace RG proportional various selectable TOLEDO is pleased to introduce held atisthe SMT Center of Competence in the speeds when production demands a bonus and added to the large palletising switching modes awarded to address diff erent application requirements. Apart the Ariva-H, its newest advancement in The integrator the order was from the full cycle switching for heating applications, the RGC1P and volume of 1800 by 1600mmcompany’s and height 2200mm users are provided with a wide Munich headquarters to coincide familiar with such can filling and packing weighing at used the checkout. RGS1P controllers include phase angle switching which can be for working range. with Productronica in Munich, ASM Assembly fastlines andhandling accurateup control of heaters andhour, light dimming applications. The a fast and reliable scale to 75,000 units per The Ariva-H combines Systems – a leading global manufacturer advanced full cycle mode is specifi cally designed for short wave infrared the high performance of the CP Range are the ‘Green Credentials’ but the layout was more of a challenge! with a popular scanner of“Supporting the retailer’s choice of production solutions for the heaters to reduce visual flickering whilst the soft start feature eliminates that it offers. We’ve concentrated on making this robot low electronics energy and easy The cans are first packed in shrink film in high inrush currents when switching them from a coldinto state, extending the canto one system that bemaintain; integrated intothan 90% industry – demonstrated more of all components acrosstwo the variants range areofidentical lifetime of the such heater. formations as 2×2, 2×3, 2×4, 3×4. These the checkout lane. allowing customers to reduce their partsLBR handling storage requirements. An the KUKA iiwa and (intelligent industrial
are then secondary packed together on a
integrated hybrid function stores from The braking utilising it for acceleration workenergy assistant). robot was featured The range offers operating voltages up to 660VAC, Ariva-H current rating up to most connects point-of-sale tray in a variety over 75 pack formations. and lowering energy consumption overall.” variant supplying material 63AAC (RGC1P), 90AAC (RGS1P; control inputs off 4-20mA, 0-10V, 0-5V, applications as a stationary systems for checkout and The of packs vary small for control and load status 1-5V orresulting external trays potentiometer; LEDfrom indication for production and, mounted on a mobile manyto other applications thatCP require weight The Range is supplied with the compact Kawasaki E03 controller which is ideal as to well aslarge, 100kA short circuit current rating UL508 with very a real challenge to handle on according platform, as the KMR iiwa duringStraight-forward ongoing tamper proof covers also available. for locating from undera a conveyor in normally redundant space. data. Ariva-H supports technology
conveyors in the available space.
programming is also offeredoperations when the optional K-SPARC palletising in a SIPLACE SMT line. software is number of scanner manufacturers, including
TheOne new series hasofaAmbaFlex’s minimum width of only 35mm up to 43 AAC at used.Technologies®, This enable programmes to be generated offline by selecting the workmore proof leading Datalogic®, Motorola/Zebra www.kuka-robotics.com 40°C and a maximum width of 70mm for the 50 AAC and 63 AAC which piece, pallet and stowage pattern; layout planning and operating simulations can position in Spiral Conveyor Solutions! provides a compact and space saving solution optimising panel space. and NCR®. also be performed enabling optimisation of the palletising operation.
www.ambaflex.com www.carlogavazzi.co.uk
www.mt.com/retail-ariva www.kawasakirobot.co.uk
Increased capacity palletising robots al ou in
GC1P and ular solid
omatically
selectable s. Apart GC1P and used for ions. The e infrared eliminates nding the
ing up to 10V, 0-5V, ad status 508 with
3 AAC at AC which space.
Ian Hensman, Kawasaki Robotics’ sales and marketing manager points out that the new arm offers the optimal flexibility demanded by manufacturers and food processors today: “The CP Range robots rank as best in class when running the standard industry takt test for large robots; 400 mm up, 2000 mm horizontal and 400mm down. Having the ability to increase palletising speeds when production demands is a bonus and added to the large palletising volume of 1800 by 1600mm and height 2200mm users are provided with a wide working range.
Low Cost Robotics R12 – the lowest cost professional robot arm in the world! Designed like a sports car it is fast and light but accurate and reliable. 500mm reach. Available in 5-axis and 6-axis versions. R17 – 750mm reach articulated arm, available in 5 and 6 axis versions plus high payload and high speed versions. R19 – A 4-axis cylindrical format robot, accurate and clean, ideal for laboratory applications.
“Supporting the high performance of the CP Range are the ‘Green Credentials’ that it offers. We’ve concentrated on making this robot low energy and easy to maintain; more than 90% of all components across the range are identical allowing customers to reduce their parts handling and storage requirements. An integrated hybrid function stores energy from braking utilising it for acceleration and lowering energy consumption overall.”
COLLABORATIVE – ST robots can work with humans as well as any other robot bearing in mind that a robot moving at speed with any kind of load will hurt you no matter what make of robot you choose (so don’t be fooled by claims you may see). ST provides full guidance for safety and risk assessment.
The CP Range is supplied with the compact Kawasaki E03 controller which is ideal for locating under a conveyor in normally redundant space. Straight-forward programming is also offered when the optional K-SPARC palletising software is used. This enable programmes to be generated offline by selecting the workpiece, pallet and stowage pattern; layout planning and operating simulations can also be performed enabling optimisation of the palletising operation.
SOFTWARE – For most people the biggest reason for not getting in to robotics is the perceived risk that the software will be too difficult. ST’s software, RoboForth, is probably the easiest to use on the planet. It’s a fact – see the testimonials on our website. We provide acclaimed manuals and tutorials plus unlimited free technical support.
www.kawasakirobot.co.uk
66
www.strobotics.com
Capable of operating 2050 cycles per hour with a 130kg payload is the claim of Kawasaki Robotics for its new CP range of palletising robots. Three new models make up the CP range, offering maximum payloads of 180, 300 and 500kg. High throughput, a wide working range and ease of programming are attributes that position the range competitively in the market. By reducing robot weight by up to 38% over the range it replaces, and enhancing the drive mechanism for the arm’s rotation (joint 1), payload capacities have been increased in line with overall performance.
www.strobotics.com PECM Issue 19
RELIABLE – ST robots work for years before any kind of attention is required. Meanwhile the robots are maintenance free.
ST Robotics are at Orwell House, Cambridge, CB4 0PP Tel: +44 1223 420288, sales@strobotics.com
Your Ideas. Realised
Tel: 01234 270770 | Fax: 01234 348803
Product News
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52
PECM Issue 19
PECM316.indd 52
NEW Thermometer Kit with Integral Timer simplifies Legionella Water Tests
Temperature specialists, TM Electronics (UK) Ltd asked engineers involved in water temperature testing how their job could be made easier. The feedback was unanimous a handheld thermometer with integral timer for one and two minute running times for hot and cold water outlets. TME listened to the comments from the 2015 Healthcare Estates Conference in October and responded quickly. Just one month later the company launched the CLEGK1 Compact Legionella Temp Kit, featuring the new MM2008 Legionella Thermometer with Integral Timer and the BSKS01-S Dual Purpose Temperature Probe – all for the special introductory price of just £120. The MM2008 features 1 minute and 2 minute countdown buttons, making it much easier to use for timing the hot and cold water tests - recommended for Legionnaires’ disease risk assessment, management prevention & testing to ACoP L8. The BSKS01-S has a fully waterproof construction which means it can be used for both running water and pipe surface temperature measurement. Main Features of the CLEGK1 • Waterproof thermometer to IP67 (MM2008) • Integral Countdown Timer on Thermometer Display • Counts down 1 minute (Hot) and 2 minute (Cold) water running times at the touch of a button • Thermometer compatible with all K-Type probes with mini plug • High Accuracy • Wide temperature range • Waterproof dual purpose probe for liquid and surface temperature measurement (BSK01-S) • Thermometer for Life Guarantee
Email: sales@tmethermometers.com www.tmethermometers.com
Product News
26/02/2016 18:36
TCL Packaging Invests In New Solvent-Free Laminator “Not only is the new laminator helping clear our order backlog, its solventfree application is ensuring we continue to exceed our environmental targets” concludes Langford.
TCL Packaging has installed and commissioned a new Laminastar 4 solvent-free laminator from French manufacturer DCM USIMECA at its new premises in Telford. This is to increase supply of the company’s packaging films. The latter part of 2014 saw unprecedented demand levels for printed and laminated packaging films across the industry. The usual seasonal demands were expanded significantly by late requests for new films to meet the labelling deadline for the European food information regulations (FIR).
“The new laminator could not begin working soon enough for our production team who have been working around-the-clock and in shifts over the Christmas and New Year break to meet demand” said Production Manager Dean Langford. “Its rapid cylinder changeover time and capacity for wide films is already taking the pressure from our existing combined coater-laminator. It has also freed up our three flexographic presses to focus fully on print production rather than supporting with coatings and treatments.
DRB GROUP First Avenue, Deeside Ind. Park, Deeside, Flintshire, CH5 2QR Tel: 01244 280280 Fax: 01244 288367
Email: Web:
sales@drbgroup.co.uk www.drbgroup.co.uk
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42 Technology and Gabler develop gum manufacturing breakthrough with Mondelez International 42 Technology has partnered with Gabler GmbH & Co. KG, one of the world’s leading providers of manufacturing process equipment, to help Mondelez International make a dramatic improvement in the efficiency of its chewing gum manufacturing process.
The company’s chewing gum brands include: Trident, the world’s number one gum brand, as well as Dentyne, Clorets, Hollywood, Dirol, Stimorol and First.
The consultancy’s role included: working with Gabler to develop a new system design, developing a theoretical model of the cooling process, advising on the final tunnel design and helping with commissioning the new equipment. Gabler then built and tested the prototype system before manufacturing and installing the final design. “42 Technology and Gabler have joined forces to develop a real breakthrough in cooling performance that has helped Mondelez International to set a new efficiency benchmark.
42 Technology was appointed by Mondelez International to work with Gabler, the company’s existing supplier of cooling tunnels, to bring a fresh perspective and drawing on its extensive experience in cooling technologies, fluid dynamics and process improvement for the food and drink sector.
The new tunnels have significantly shortened the time needed for gum cooling and conditioning, one of the most time- consuming steps in the manufacturing process and are also 40% smaller than the equipment they replace.”
The aim was to identify new ways of using combined conductive and convective cooling technologies to help speed up the cooling of extruded gum before it is scored, shaped and moves into the conditioning phase.
In addition to helping design the new cooling tunnel, 42 Technology has also advised Mondelez International on a number of other opportunities to further optimise process efficiency through improved control of temperature, humidity and other environmental factors.
Miles van Niekerk, Associate Director, new process development at Mondelez International said -
,,
The two companies have pooled their resources and complementary expertise to develop a new generation of high-speed cooling tunnels that are helping Mondelez International to significantly increase production throughput, reduce work in progress by 60%, and to further optimise downstream processing and packaging.
The new high-speed cooling tunnels, which have now been installed in three global locations highlight the significant commercial benefits of bringing together partners with complementary skills.
,,
About 42 Technology 42 Technology is a product design and development consultancy that specialises in creating innovative products for consumer and business markets including medical and healthcare, industrial, packaging and dispense, consumer, food and drink, and energy. The company’s core team of industry-experienced product designers and engineers works closely with academia, selected associates and partner companies to offer a cost-effective and efficient approach to new product development. 42 Technology is the perfect partner for SMEs, as well as larger international brands, as it offers everything from assistance with technology strategy and management through to new product creation and UK-based or off-shore manufacturing. For further information please visit or contact: www.42technology.com
About Gabler GmbH & Co. KG Gabler designs, develops and manufactures equipment and advanced production systems for manufacturing companies across the world, as well as equipment for use in R&D laboratories or for small-scale batches. The company specialises in confectionery and pharmaceutical manufacturing processes with particular emphasis on extrusion technologies. Gabler was founded in 1906, is based in Malsch, southern Germany and is now a fourth generation family business where the mix of experience and innovation within the Gabler family continues throughout the entire team. For further information see www.wls-gabler.de
Product News
Do you have the need to hire a bottle capping machine on a month to month basis? Short, sporadic batches becoming a problem? At Cap Coder we have learnt to meet the needs of smaller contract packers who don’t always require automation month in, month out. As of January 2015, we will be holding stock of our popular CC570 in-line bottle capping machine ready to be hired at short notice. Perfect for medium production rate bottle capping/closing at up to 40 bottles per minute. The machines are fully assembled ready to go. You simply buy the tooling change parts to suit your product. For more information about hiring a machine or details of any other Cap Coder equipment, please feel free to get in touch. Call us on 01865 891466 or us email via the contact form.
AUTOMATION STEPPING STONES
FIBC
Automation stepping stones
FIBC is a flexible container that is used for transporting large dry and flowable products. Known also as Bulk bag and big bag containers they are used as an industrial container for products such as sugar, plastic granules, sand or chemicals.
SME’s jump on the automation bandwagon with Endoline’s simple pointers It’s official; SME’s in the UK are on the up with growth and start up business rates returning to pre-crisis levels. Considered the back bone of the economy SME’s contribute a staggering £1.2 trillion to the UK each year.* Now, in the face of a national living wage, coupled with the growth of affordable systems, SME’s are beginning to take a leap of faith into the fast paced world of automation. According to reports 2016 is set to be the ‘tipping point’ for manufacturing technology, with increasing numbers of companies embracing robotics and automation. While this rise in the manufacturing sector has sparked employment debates, companies are realising the potential to improve output and efficiencies through automation. www.endoline-automation.com
See the Lasercomb ProDigi NEO 2517 at Sign & Digital Stand K50
ESL’s role in the development of Shell Tower and the Southbank
Exhibiting at Sign & Digital UK for the fifth successive year, finishing equipment specialist Friedheim International will be highlighting the capabilities of a Lasercomb ProDigi NEO 2517 multi-functional digital cutting system on its stand.
ESL’s Turbo Dustless Blasting Systems clear the way for the redevelopment of the iconic Shell Tower
A modular tool concept is a key feature of the ProDigi NEO multi-functional digital cutting system, and the machine being demonstrated on the stand will incorporate a 1 kW milling spindle with tooling for handling several different types of materials, as well as an oscillating cutting unit. www.friedheim.co.uk
Flomat Bagfilla International Flomat Bagfilla are the industry leaders for products in FIBC handling, in the past 30 years FPE Global Ltd have developed a full range of FIBC solutions under the Flomat brand that can handle all types of bulk materials. Given the challenge of creating a solution for filling, discharging and dosing bulk bags, the Flomat Bagfilla range was born. www.fpeglobal.com
www.capcoder.com
On the ProDigi NEO a new front end PC featuring a colour touch screen allows the operator to choose between automatic or manual modes, as well as accessing the tool database. The PC also provides operational diagnosis.
FPE Global are leaders in FIBC handling, not only by designing and engineering Powder Processing systems that can fill, discharge and dose FIBC but also as the designers of the industry leading Flomat Bagfilla FIBC range.
London’s Southbank is set to be transformed by a unique mixed-use development with the famous Shell Tower at its heart. The famous building will remain the centrepiece of the new site, occupied by Shell. The Tower will be complemented by eight new buildings. Approximately 800,000 sq ft of office space along with around 80,000 sq ft of new retail units, restaurants and cafes will be accompanies by 800,000 sq ft of residential space incorporating up to 790 new homes. The development is planned for completion in 2019. ESL’s wide range of world-leading industrial cleaning equipment and machinery is available for sale or hire. www.ecoblastsupplies.co.uk
More precision for modern printing B&R presents advanced vibration compensation at drupa At this year’s drupa, B&R will be unveiling its new High Precision Motion Control technology for industrial printing presses. By boosting positioning precision by up to 80%, it promises a significant improvement in print quality. Another highlight at Booth E37 in Hall 13 will be B&R’s programmable safety technology – which makes implementing safety solutions more cost-effective than ever. A growing number of today’s printing presses feature a streamlined mechanical design that utilizes light-weight materials. The resulting increase in vibration and lag error, however, lowers precision and ultimately diminishes print quality. With the advanced compensation offered by B&R’s new High Precision Motion Con-trol – even the fastest presses can print with impeccable quality. www.br-automation.com
Packaging Europe | 141 |
ABB to supply hoists for South African diamond mine expansion ABB will supply one double drum hoist for personnel and material conveyance, two friction hoists for production, and one single drum hoist for service duty. ABB will provide the design, supply, manufacture, installation and commissioning of all four hoists, including hoist mechanicals, motors, and electrical drive and control, all certified to the highest safety integrity levels (SIL). This is the first time that multiple, turnkey large friction mine hoists are delivered to the South African mining industry. The installation will commence in July 2018. All four hoists are due to become operational in April 2020. ABB (www.abb.com) is a leader in power and automation technologies that enable utility, industry, and transport and infrastructure customers to improve their performance while lowering environmental impact. www.abb.com
The new Hitachi UX
Why install a CSL Conveyor solution?
Comfortable - Available in three models – Basic Entry Level, Flexible Standard and Premium – the new Continous Inkjet Series UX features a new cartridge-type system, which makes ink replacement clean and simple. The ink and make-up cartridge bottles can be used right up until the last drop which prevents wastage and eliminates the need to dispose of them separately.
Conveyor Systems Ltd offers a wide range of conveyors to create customised product handling systems for moving anything from small poly bags, cases, totes and pallets up to 2 tons in either simple transit or accumulation modes and can also be utilised for feeds to and from palletisers, wrappers, labellers, strappers, sealers etc.
Cost effective - Using the latest patented Hitachi technology, the cost effective UX Inkjet incorporates a new fluid consumption reduction system, making it one of the lowest consumers of make-up available on the printer market, thereby significantly reducing running costs. Robust - The printer’s cabinet is IP65 rated for dusty environments. It can be washed down when necessary making it suitable for applications in the likes of the meat and dairy industries. It may also be used in temperatures ranging from 0 to 50oC.
Systems can be based on modular designs to provide a simple and cost effective scheme or alternatively, a bespoke solution can be proposed depending on requirements and/ or budget. Whether you are handling small items, trays, cartons, totes or pallets - CSL can provide an effective conveyor solution for you. www.conveyorsystemsltd.co.uk sales@conveyorsystemsltd.co.uk Tel: 01283 552255
www.hitachi.com
Eclipse to Showcase Magnetic Technology for Renewable Energy Applications at All-Energy Exhibition
FANUC breaks world record for industrial robot production
Equipment helps food to stay fresh and safe
Production doubled in the last seven years
Eclipse Magnetics will be exhibiting a range of magnetic materials and assemblies at AllEnergy Exhibition and Conference in Glasgow from 4 – 5 May. On display will be a variety of magnetic solutions for power generation applications, and magnets and magnetic assemblies for motors, actuators, machines, and drives applications.
Echternach, Luxembourg – Earlier today, FANUC Europe announced it has a worldwide installed base of over 400,000 industrial robots, a new world record for the industry.
On show will be Jenton’s Ariana range of equipment for the food automation market. The latest Ariana pack stacker will be on working display alongside the BCS converger range which is designed to work with all major rollstock thermoforming machines.Ariana also specialises in seal testing equipment for ready meals and other gas flushed packs and a working test module will allow visitors to test any samples they bring along to the exhibition. In addition to working equipment, information will be available on pad placing, diverging and pick andplace equipment from the company. Also at the three-day event will be bag sealing equipment from Jenton’s partners Emplex, in Canada. Continuous bag sealers are available for medical, food and general packaging applications with a wide variety of options such as vacuum, gas flush, trim and validated seals.
Magnetic Assembly Solutions Eclipse designs, produces and supplies magnets and magnetic assembly solutions for the varied application requirements of a diverse range ofmagnet generator designs and rotor assemblies. All-Energy Exhibition and Conference 2016 Visit Eclipse Magnetics at All-Energy Exhibition and Conference 2016 on stand E41, at the SECC in Glasgow from 4 – 5 May 2016. www.all-energy.co.uk
The recent drivers behind reaching this major milestone have been the popularity of the FANUC R-2000i Series, LR Mate series, and the CR-35iA, collaborative green robot. The FANUC R-2000i and LR Mate series are the company’s highest selling robots, while the collaborative robot has attracted new attention of customers. Collaborative robots brought a variety of benefits to the manufacturing plant floor including improved employee welfare and increased cost savings. At the same time, demand from manufacturers in China to transform their factories with new and emerging technologies has fueled production for industrial robots. www.fanuc.eu
www.jentonariana.co.uk
Packaging Europe | 71 |
Fanuc The LRMate 200iD ROBOTIC POT SWAP UNIT RESPONDS TO RETAIL DEMANDS
In response to rising retailer demand for mixed product trays, FANUC has collaborated with integrator Pacepacker Services to engineer a first-of-its-kind robotic pot swap tray loading system. The robotic pick and place unit swaps pots between cardboard trays combining FANUC’s LR Mate200iD robot with Pacepacker’s new Mixed Tray Loader (MTL) technology.
It provides a flexible and compact solution for generating the assorted trays of product that are increasingly being requested by retailers. “The trend towards pallets of mixed products, driven by retailers requiring smaller, more frequent deliveries, is now being extended to case level. Mixed trays or cases allow supermarkets to offer a broader choice of product sizes, flavours and variants and to keep their shelves replenished without having to hold a lot of stock.
Equally, convenience and inner-city stores are finding that mixed cases or trays allow them to offer a far wider product range on restricted shelf space,” says John Rainer, Regional Sales Manager from FANUC UK, explaining the rationale for the launch of the robotic product swap unit. The robotic pot swap system can be configured as either an offline or an online system. The system developed and installed by Pacepacker Services at the UK dip producer was an offline execution, positioned over twin lanes of filled trays. The picking heads remove one line of product from the first tray, and place it into the second tray. The process is then reversed to swap items in both trays. In an online configuration, the MTL would typically be fed by multiple product lines, with a robot picking a row from one conveyor and placing it in a tray, then picking a row from another conveyor and so on.
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Measuring pH In A Food-Safe Environment Food processing covers a wide range of activities all of which require both food safety and quality standards to be met to ensure that consumers receive high quality products. One of the more vital parameters that plays a part in this is pH since it governs both physical and chemical reactions during food production as well as inhibiting the growth of pathogens. This image shows pH sensors being used in a process skid that includes a dosing system.
Ian Webster, Hygienic Processing Segment Manager at B체rkert UK, looks at the importance of measuring pH and the most efficient methods of achieving accurate pH control. Ever since we discovered cheese and alcohol, man has been controlling the acidity of food in order to create different products. With an extraordinarily detailed understanding of how pH can affect the look, taste and quality of a food product, we have now introduced precise pH control as part of general food processing and safety programmes covered by national regulatory bodies. Every micro-organism has a minimum, optimum and maximum pH for growth. Useful yeasts and moulds, for example can grow at low pH, but 4.6 and below is generally considered the level that will prevent the growth and toxin production of harmful pathogens. However, going too far can have detrimental effects of its own. It is therefore necessary to have suitable testing equipment that can measure pH with sufficient accuracy in order to ensure product quality and compliance with food safety regulations. Monitoring of pH is also very important in the food production process especially in dairy products. Milk is tested for impurities and signs of in-
fection both upon collection as well as at the point of delivery, while beer and wine producers rely on precise pH readings to determine the taste and quality of the final product. Finally, when a particular process is finished, an automated cleaning procedure can be used to prepare the production system for the next batch; hence, ensuring correct pH levels are maintained is also crucial in the hygiene management system. Accuracy Selecting the most appropriate pH meter requires three main points to be considered, the first of which is resolution and accuracy. At the cheaper end of the market, pH meters will typically have a resolution of 0.1 pH units which will be sufficient for some data recording functions. However, some of the least expensive meters may have an accuracy of plus or minus 0.2 units. In other words, if the meter reads 4.5, the actual pH of the product could be anywhere from 4.3 to 4.7. This might present a problem if the pH of your product were to exceed the safe limit of 4.6 for example. This can have significant consequences for food producers as they are required to either re-process any batches that fail to meet the criteria or destroy them.
Commercial pH sensors have a range of accuracies to account for different applications but 0.01 units would be expected in continuous food processing systems, where the sensors can also be set-up to trigger warning signals that allow corrections to be made before the process is out of specification. Calibration Accuracy is also dependent on correct calibration and temperature compensation. Calibration is completed using buffer solutions of precisely known pH values whilst also measuring the temperature. Since the pH of the solution is a function of its temperature, as the temperature changes, so does the pH, despite the concentration of acid or base remaining the same. [1] It is therefore also important to ensure that measured pH values are compensated to allow for the difference between the measured temperature and the reference temperature, which is normally 25째C. In this way various pH readings can be directly compared without being affected by the temperature of the process.
Electrodes Glass diaphragm electrodes use a reference electrode, suspended in a buffer solution of pH7 - that is compared to the measuring electrode and as such this design is used for a wide range of applications. For more robust applications single element electrodes made from enamel-coated steel or a polymer that use pH sensitive coatings are also available. B端rkert uses a modular system that allows process engineers to build the most suitable pH sensing system, depending on the application. A variety of probes designed to operate in varying conditions and media can be combined with PT1000 temperature sensors and connected to a transmitter / controller such as the Type 8619 multiCELL. Combined with a choice of fittings and sealing materials as well as EHEDG certification, the product range can be specified to suit most applications within the food industry. In general glass pH electrodes are not suitable for food applications due to the risk of broken glass fragments contaminating the process. Further-
more, many designs of pH electrode need to be removed from the process stream before the CIP process can be completed which requires expensive retraction systems to be employed, creating extra work and inconvenience for the end user.
A variety of probes and temperature sensors designed to operate in varying conditions and media can be connected to a transmitter / controller such as the Type 8619 multiCELL seen here mounted into a stainless enclosure.
One solution could be the Type 8201 pH measuring system, which employs a hygienic, robust and glassfree design that can withstand high temperatures and can be sterilised in situ. In addition, the smooth enamel external surface of the probe inhibits the process medium from sticking to it and is very easy to clean. By using industry standard signals, these pH sensors can either be integrated into an existing process control system or used in conjunction with other control components. This
can provide localised feedback for a closed loop control system, for example to ensure the correct dosing of a product with pH sensors both before and after the process. Material specification of the sensor body and the sealing components can also play an important role in the performance of the pH sensor within the wider process control environment. This is particularly true when dealing with extremes of pH which can be highly reactive and corrosive. Sensor manufacturers with specialist knowledge in this area should be available to support customers to ensure that both process and hygiene control are properly managed. The wide variety of manufacturing processes in the food industry that require pH levels to be monitored and controlled means that sensors need to selected accordingly to suit each application. Media purity, temperature and pressure all need to be accounted for as well as portability and calibration frequency. All of these areas should be carefully considered along with expert technical advice from manufacturers such as B端rkert.
Commercial pH sensors have a range of accuracies to account for different applications but 0.01 units would be expected in continuous food processing systems.
Mitsubishi Electric The Art Of Slicing ROBOT KEEPS NEWTECH AT THE CUTTING EDGE OF CAKE SLICING When automation OEM Newtech looked to design a new ultrasonic cutting machine for the bakery industry, it turned to Mitsubishi Electric for a fast, efficient, flexible and clean robotic solution. The result is an innovative machine design that can cut cakes to the highest levels of precision, working flexibly for different portion sizes and quantities, and eliminating problems of damaged product. Based in Bedford, Newtech is a specialist supplier of standard machines which provides today’s food manufacturers with cost-effective, high quality automation systems, with the highest levels of flexibility to meet ever-changing market demands. One of the company’s innovations is the adoption of ultrasonic cutting technology, giving best-available cut quality for products which are difficult to process using conventional methods.
With a new machine design, Newtech set out to overcome these limitations by combining ultrasonic cutting with robotic actuation of the cutting blade. For an out-of-the-box solution which would be easy to integrate into the machine, Newtech turned to Mitsubishi Electric. The solution offered by Mitsubishi Electric was built around an RF13 13kg payload, six axis robot, mounted within a stainless steel cell. One of the fastest robots in
its class, the RF13 is also highly dextrous, being capable of reaching all the way behind itself and also very close to its base, giving a highly flexible and compact working area. The robot is controlled via the Mitsubishi Electric MELSEC iQ Platform. The iQ Platform is a multi-functional automation environment which incorporates Q series PLC control and uniquely, an integrated robot controller within the same rack. www.eu3a.mitsubishielectric.com
Profile Technology
Conveyor Technology
Linear Motion
Factory Equipment
MODULES AND MUCH MORE
SPU 2040 Accumulating Pallet Recirculation Systems with automatic return of pallets
mk Profile Systems Limited a company of the mk Technology Group Unit 2·Wolds Farm Business Park Kinoulton Lane·Kinoulton·Nottinghamshire, NG12 3EQ Phone +44 (0)1949 823751·Fax +44 (0)1949 81270 www.mkprofiles.co.uk·info@mkprofiles.co.uk
Product News
Lighthouse New Website
New flow regulating hopper : First displayed at the CFIA exhibition in Rennes (France) from March 10th to 12th
We are currently developing a brand new web site. Our head of web design at Lighthouse, Richard Bottrill, is aiming to introduce new features, facilities and faster navigation.
Precision Measurement Machine Vision System
We invite you to join us on our stand in order to discover our new feeding hopper, specifically designed for the high speed lifting of compact products.
‘Technology is constantly evolving and our existing site has worked extremely well over the last few years. With the launch of new products, we are keen to develop our online presence further still. Through a combination of customer feedback and technical data from visitors, we can build a clear picture of the functionality needed to keep us at the forefront of the industry.’
The cylinders which have been set on this new hopper bring a solution for the lifting of pasty products which come out of production in the form of blocks (purees, fresh cheese).
21st January 2016. Final set-up and installation of a new vision system machine for precision measurement. Checking focus and mechanical settings for tooling. Dual axis servo control with linescan and areascan sensors. Keep up to date with our latest photos by following us on Instagram: www.instagram.com/industrialvision
These cylinders enable to model the product so as to fit the diameter of the tube formed by the Liftvrac and thus avoid any risk of obstruction.
If there’s anything you’d like to see on our new site, please contact uswith your suggestions. www.lighthouse.uk.com
www.liftvrac-convoyeur.fr
Flexible solutions for fish industry A real change in philosophy, this commissioning of 5 ECOWRAP ETW 202 type in Poland! We achieved a support towards carton mechanization of 4 formats and the future possibility of increasing speed from 80 up to 120 packs/min to satisfy the increasing demand, here is the flexibility our customer was looking for. A partnership was entered between customer's packaging department and ETPACK SPRINTER's mechanization department to design the best blanks, for mechanization and to meet marketing departments' expectations of our customer's partners, especially focusing on easy opening. Today, high increase of salmons sales is for ETPACK SPRINTER the best judge of reliability and customer's satisfaction. www.et-pack.com
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Tel: +33 (0) 298 946 999
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contact@et-pack.com
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Product News
Label Print & Apply Machines Features of Batch Print & Apply Main Use: Batch production – where most of the variable information remains constant between products.
Advanced Labelling Systems Ltd offer both On-Demand and Batch Print & Apply labelling machines.
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Both come with the ALS unique 2-Year, on-site warranty
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Both feature the ALS lifetime printhead warranty, when used with ALS labels and ribbons
Common features of our Print & Apply machinery •
Both machines come in 3 size options: 4-inch, 5-inch, and 6-inch
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Both can apply labels with direct wipeon method
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Optional add-on modules: Blow-on, Tamp-On, Swing-On
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Both feature fully integrated electronics and common interfaces
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Both have ribbon-save, which minimises the use of thermal transfer ribbon when printing long labels
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Both are compatible with the off-line desktop Chess-64/0X printer range
Features of On-Demand Print & Apply Main Use: Where the information on every label could potentially be different, such as; mail-order/logistics and pharmaceutical serialisation. •
Labels are printed at the time of application (Real-time)
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Multiple application methods
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Control: Variable data, specific to each product, can be managed better. E.g. variable weights, serial numbers, tracking numbers, mailing addresses.
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On-demand label application
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Labels are printed into a buffer loop before application
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Very high labelling speeds while still maintaining high throughput rates
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Application Speed- Significantly faster application speeds, as labels are taken from the loop and not restricted by the print engine
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Easy integration into tight spaces and in product handling units such as wraparound devices
Label scanning and verification equipment: We support our label print and apply applicators with scanners that can check linear barcodes and 2-D matrix codes, either prior to application or on-pack after application. For reading of text, codes and graphical content, then complete vision cameras are available to validate that the complete label has been printed correctly and in many circumstances, will also confirm the label has been applied to the correct product and in the right position. The possibilities are endless! Confused? Don’t worry- Tell us what you need to label and we’ll advise the right type of machine.
Adpak achieves Safecontractor accreditation for the 8th year running
Cama Racing Team: Innovation not only in Packaging Systems
Clifton Invests In Uteco Crystal HD Flexo Press
Adpak Machinery Systems Ltd has once again been awarded accreditation from Safecontractor for its commitment to achieving excellence in health and safety.
CAMA Group is a leading producer of automatic cardboard packaging systems. Its owners, the brother and sister team of Daniele and Annalisa Bellante, launched its sports division in 2014. The Cama Group Sports Amateur Association promotes TEAM BUILDING for its employees outside the work environments.
A brand new 8 colour high definition flexo printing press.
Safecontractor is a leading third party accreditation scheme which recognises very high standards in health and safety management amongst UK contractors. Employing 36 people, Adpak have been providing packaging solutions across a variety of sectors since 1987. The company’s application for Safecontractor accreditation was driven by the need for a uniform standard across the business. Safecontractor accreditation enhances the company’s ability to attract new contracts and its commitment to safety will be viewed positively by its insurers when the company liability policy is up for renewal. www.safecontractor.com
Solid business performance, underpinning a love for sport and, above all, shared corporate values were the key to the rapid development of a modern, dynamic, well organised club. The club reflects its members’ needs and consistently promotes high quality, ethical and organisational standards. The club is involved in wide range of sports disciplines, but road and off-road cycling stand out, as they are practised at different levels by many enthusiasts within the company. This led to the creation of the CAMA Racing Team. www.camagroup.com
The state-of-the-art wide-web presses have the ability to print up to eight colours in high definition and both boast ink management control system and a 100% camera inspection systems. This has hugely increased the print capacity which will ultimately offer faster lead times and greater efficiency, benefiting the company and customers alike. www.cliftonpackaging.com Tel: + 44(0)116 289 3355 Fax: +44(0)116 289 1113 Email: info@cliftonpackaging.co.uk
HRS Heat Exchangers By Matt Hale, International Sales Manager
It is easy to see why anaerobic digestion (AD) has become such a popular technology in the food processing industry. Currently over 400 AD plants are generating more than 500 MW of energy - yet the potential for UK AD is as much as 80 TWh of methane (equivalent to 30% of the UK’s household gas demand) according to ADBA*. AD utilises waste streams and co-products, often removing the need for other waste treatment technologies. It can provide heat and electricity for processing operations and produces a valuable end product in the form of digestate biofertiliser.
However, although plants of all scales can provide these benefits, not all of them are as efficient as they could be. With recent changes to support schemes for renewable energy in the UK, it is important to make sure that every available watt of power is utilised in some way. That means that everything, from the obvious, such as the amount of biogas produced and the efficiency of combined heat and power (CHP) units, to the less obvious, like utilising wasted CHP heat to further improve the process, must be examined and maximised where possible.
Obviously the best time to do this is as early as possible in the planning process, so that equipment can be appropriately specified and the plant designed around an optimum layout. However, while this might be the ideal situation, chances are that project managers and plant operators can improve the overall efficiency of almost any existing AD plant if key considerations are taken into account.
1 Assess your entire process from obtaining feedstock to exporting digestate. The first step of any optimisation process is to understand what you are (or will be) doing. Analyse each step to see where wastage may occur and how it could be improved. For example, could you pre-warm feedstock before it enters the digester or, if you are already doing so, could you re-use heat already generated elsewhere? Does the proportion of heat to electricity generated match your requirements? If you are still planning, would another unit suit your needs better? If you are already operating your plant, could you re-use any heat which may be wasted? Also look at your digestate - could you add value to it, perhaps through pasteurisation or concentration?
4 Aim for continuous processing. Having to stop and start parts of your plant can be inefficient, even if the process is automated. Using multi-tank pasteurisation or digestate concentration systems means that while one tank is being heat treated, the other/s can be filling or emptying, ensuring that the rest of the AD process is not interrupted. On top of this, HRS multi-tank systems use four level temperature probes in each tank, three in the bottom of each tank and one in the top – so that the tanks can be filled to half capacities should the demand or flow drop off, allowing for continuous and flexible production of digestate.
2 Maximise the efficiency of all processes, from energy generation to heat exchange. Check the efficiencies of all processes, whether in terms of thermal transfer, electrical output or gas generation. Keeping equipment, particularly heat exchange surfaces, clean and maintained will help it to operate at its maximum efficiency. When specifying or researching equipment, remember that over the operational life of a plant, the effects of even a small difference in overall efficiency could be considerable. For example, a 0.25% increase in the electrical efficiency of a 500 kW CHP unit could be worth more than £7,000 over the life of a plant at current wholesale prices. Likewise, reducing the volume of digestate produced by the plant may create other efficiencies, such as reducing the amount of storage required (reducing capital costs) or transport requirements (lowering operating costs).
3 Re-use heat which would otherwise be wasted. It may not seem obvious at first, but any large quantity of heat has a use, including the heat given off by radiators (such as the cooling loop of a CHP engine), heat exchangers or other parts of the process. If you don’t already pre-heat your feedstock, doing so may increase the thermal efficiency of the digester, while if you do already pre-heat, using heat from elsewhere in the process will be cheaper (and greener) than creating heat just for this purpose. Likewise, pasteurising the digestate using recycled heat circumvents the need to install an additional heat source such as a biomass boiler, which could add hundreds of thousands of pounds to a project. Many pasteurisation systems on the market simply dump the heat used. HRS systems recycle the heat, making them up-to 70% more efficient than a typical ‘heat jacket’ type pasteuriser and allowing this heat to be reused, either elsewhere in the process (for digestate concentration for example) or exported to other processes.
Carolyn Wheeler, Sales & Marketing Coordinator HRS House, 10-12 Caxton Way, Watford Business Park, Watford, Herts, WD18 8JY Tel: 01923 232 335 Direct Email: carolyn.wheeler@hrs.co.uk Email for publications: info@hrs-he.com
Without these probes, the system would be put on a ‘go slow’ in order to wait for the tanks to fill, which would require more heat as well as incurring the expense of slowing production or shutting the system down and restarting.
www.hrs-heatexchangers.com
CSB System
CSB SHOWCASES SOLUTIONS FOR THE SMART FOOD FACTORY
CSB-System provides control and automation of the flow of information and materials throughout the entire value chain, from receiving via production and internal logistics up to final dispatch. These modular and scalable industry-specific solutions are suitable for any type of operation, and the CSB portfolio also comprises solutions for mobile collection of internal and external data.
The system calculates the input of goods and resources, optimises recipes as well as processing and refinement procedures, and maximises delivery capabilities. At the same time, it guarantees high product quality, traceability and food safety. With an increasing focus on the Smart Food Factory of the future, CSB will present information about IT solutions that can be used for production automation as well as for online machine data capture
and automated data capture. Other field-proven components in this area, such as mobile company applications, cloud solutions, RFID and software-aided maintenance will also be demonstrated. Also on show will be CSB´s image processing technology. Among its benefits, this enables fully automatic classification and sorting of raw materials based on defined criteria, which leads to optimised control of production and elimination of rejects
CSB-System AG An FĂźrthenrode 9-15 D-52511 Geilenkirchen
Tel: +49 2451 625 430 Fax: +49 2451 625 291 Email: info@csb-system.com www.csb.com
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PROSEAL LAUNCHES LARGE CAPACITY TRAY SEALER Heat sealing specialist Proseal has introduced a new tray sealer specifically designed to handle very large food trays.
The GT5exSD is fully flexible and adaptable to handle any type of packing operation, including MAP gas flushing, Vacuum MAP sealing, skin packaging below and above the flange, and Skin Deep.
Maximum throughput is achieved thank to Proseal’s Pro-Motion system, which uses following motion and intelligent buffering technology to enable trays to feed continuously into the sealer without stopping.
Customers can simply select the format types they require and these can be added to or taken off at any time.
An auto-detect product flow monitoring system regulates the speed of the infeed conveyor according the amount of trays being supplied. This typically increases speeds by up to 30%.
This allows food manufacturers to change their pack formats in line with customer demands without having to invest in new equipment.
Proseal’s E-seal® technology meanwhile provides high quality seal reliability to meet the stringent quality requirements of the food retail sector while delivering a 92% reduction in energy usage, which offers valuable cost savings and sustainability benefits. Equally important, the machine boasts the most hygienic design of any tray sealer with rapid strip down of the product handling conveyors allowing deep cleaning to be carried out quickly and easily.
Another advanced feature of the GT5 range is its Pro-Tect user login security system, which provides different levels of authorisation access for individual personnel. The system keeps a log of information inputted for full traceability in the event of any problems, and any attempt to log in above a person’s level of authorisation will also be registered and recorded. The GT5 retains Proseal’s renowned rugged construction to food industry approved hygiene
standards with full wash-down protection. The company’s established ‘Auto Tool’ connection system enables tool changes to be carried out in around five minutes, while downtime is further minimised by the use of quick-change conveyor belts, and an auto-lock film reel holder. The retention of valuable pneumatic functions means the machine can also offer additional benefits such as date coding of pre-printed film
Proseal UK Ltd Tel: +44 (0) 1625 856600 Fax: +44 (0) 1625 856611 Email: info@prosealuk.com Website: http://www.proseal.com
Retail stacks that are pleasing to the pallet By Paul Wilkinson, Business Development Manager, Pacepacker Services Stack ‘em high, sell ‘em cheap was once a palletising tactic confined to wholesale outlets. Yet nowadays, it’s not uncommon to see pallet loads, especially around busy seasonal periods, carefully positioned on supermarket floors. More complex patterns, combined with revisions by the Health & Safety Executive (HSE) to the L23 manual handling guidance (Manual Handling Operations; Regulations 1992), is proving to be catalyst for automating palletising operations. It might seem like a giant game of Jenga, but given that back injuries from manual handling are a major cause of occupational ill health, palletising is no game. Well over a third of injuries lasting three-days or more reported annually to the HSE are caused by manual handling. Switching from stacking pallets by hand to automated solutions, is far less risk averse. It can also significantly increase your production output and save on transport and labour costs. Different strokes for different stacks There are a whole host of stacking patterns. The actual design will ultimately depend on the where the pallet is destined for, e.g. shipping container patterns would be different to a wholesaler like Costco. Again, stability is vital and in most pallets you won’t see the same pattern repeated layer upon layer. Like building a brick wall, most cases are arranged to interlock. One exception tends to when stacking rigid cardboard boxes of similar size. Here, it can actually increase the rigidity of the overall pallet if each row is mirrored. For those heading to the retail stores, packaging labels are also orientated to face outwards on all four sides.
Weighing up the risks If you are currently stacking pallets by hand, it’s important to give consideration to a number of factors. Manual handling hazards are wide ranging.
The recent revisions suggest that when lifting at waist height, it’s around 25kg for men and 16kg for women. The trouble is, pallet layers start at ankle height and often reach above shoulder height, and the advisable weight limits drop significantly to around 10kg for men and 7kg for women.
Although application driven, unusually shaped or unstable loads, excessive weights, stooping and twisting in cramped workspaces can increase the Many bulk loads, from sacks of rice likelihood of a workforce injury. to cases of beverages, exceed these advised limits. And if you look at bulk When assessing risks, palletising opanimal supplies, such as bedding hay, erations are advised to study first the stacks can reach up to 2.4 metres, weight of what’s being lifted and the which is impossible to manually stack frequency and distance that the load safely. is being carried. For lifting, it can be helpful to use the 5x5x5 equation does the load mass weigh more than 5kg, is it carried further than 5 metres and does the person do this activity more than 5 times a month? If the answer is yes, this could imply a significant lifting activity. In terms of manual weight handling limits, even with the new HSE guidance there are no hard and fast rules.
The art of creating stable stacks Whether you are palletising bags, pouches, cartons, boxes, pails, buckets or drums, the ultimate stability of your stack is paramount. Of course, you want to be an efficient operation and getting as much product onto the pallet as possible within the appropriate weight and height limits plays a part in this, but not at the detriment of other people’s safety. Outside of these primary aims, other factors to consider are bar code scanning or the ease of picking or de-packing the stack by the customer.
Leaving gaps between boxes can help to create a stable stack, and an automated programme can do this repetitive task consistently. Retailers are also calling for more mixed pallet loads in an effort to pare down stockroom inventories. A robot can be configured to differentiate light from heavy packages, which means they can palletise a variety of case sizes of products on one pallet without compromising the stability.
base pallet load being sufficiently strong to carry the load of the pallet above. The weight of the upper pallet must be evenly shared by all sides of the bottom stack, which articulated robotic arms can successfully accomplish. Pacepacker Services contact: Paul Wilkinson, Business Development Manager T+44 (0)1371 811544, F +44 (0)1371 811621, E paul.wilkinson@pacepackerservices.com
There’s also an emerging trend for the double stacking of palletised loads. Although this technique increases your storage capacity, to do double stacking successfully depends upon the
www.pacepacker.com The Pacepacker brand has a rich history spanning 40 years in the design and manufacture of automatic packing systems. This includes pick and place solutions, sack placers, weighing machines, bagging systems, stitchers, heat sealers and robot palletising systems for companies working in materials handling (animal feed, aggregates, potatoes, grain etc.) and the food industry. For over 15 years, Pacepacker has worked as a system integrator, supplying FANUC robots as part of an integrated
Packaging Europe | 5 |
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PLC HMI ALL IN ONE
"Unitronics offers the most cost-effective answers" Rick Gallimore, Innovative Automation and Controls, Inc.
In the picture – Packaging Machine controlled by Unitronics V1210™ and SAMBA 4.3™. Bimetec BV, Netherlands.
3.5"
7"
4.3"
Unitronics is a pioneer in the manufacture and design of PLCs with integrated HMI and on-board I/Os - rugged PLC product lines that meet a diverse range of requirements. You program your entire application in a single, intuitive software environment, and benefit from premier technical support, both provided at no extra cost.
SAMBA - Unbeatable price - performance ratio CANbus (Optional)
Microcontroller with onboard I/Os 3.5", 4.3" or 7" integrated color-touch HMI Serial, Ethernet and Modbus communications Software & Support included at no extra cost!
On-Board I/Os Digital and analog RS232/RS485 programming port in 3.5” model (USB in 4.3” model) Ethernet (Optional)
Epsom 2 Keys Business Village. Keys Park Road, Hednesford, Staffordshire, WS12 2HA Tel: +44(0) 1543 271899 sales@alldrivesandcontrols.co.uk www.alldrivesandcontrols.co.uk