Feature Materials handling & conveyors Handling solution quadruples output
commissioned utilised a number of innovative products to optimise opera- tional efficiencies for the publisher. TGW’s Commissioner acts as dynamic buffer to temporarily store and release totes for future sorter waves and a dual split tray sorter operates at high speed whilst discharging the books accurately and with care.
Automated warehouse solutions provider, TGW Limited has installed a fully integrated materials handling solution for Wiley, one of the UK’s leading publisher distributors
n 2012 Wiley’s European Distribution Centre (EDC) in Bognor Regis, West Sussex shipped 10 million units to customers in 159 countries across 3.3 million order lines. To provide additional capacity for
I
growing order volumes and to optimise accuracy and time to market, Wiley entrusted TGW with the fit-out of a 153,000 unit within the 320,000ft2 single site
facility.The solution that TGW designed, installed and
bespoke conveyor system from LB Foster Materials Handling has been installed at MINI Plant Oxford. The solution presents a constant supply of wheels to the fitting operators on each side of the production line in the most efficient and ergonomic manner.
Bespoke system for MINI A
The main driver for the new equipment was that the wheel fitting position needed to be moved further up the production line. Consequently a conveyor system was required and possible improvements to the wheel fitting operation explored. To meet the brief, LB Foster, the Leicester-based materials handling specialists, designed and manufactured zero line pressure accumulating roller conveyors complete with pop up transfers and tilting units for each side of the line. These conveyors are now used to transport the wheels in the correct sequence from the ground floor lifts to the cars as they progress down the line. Gary Bale is the managing director of LB Foster Materials Handling, says: “Due to the time restraints on this contract it was important we successfully completed the project within the tight deadline specified. To eliminate production downtime, we carried out the installation during a planned shutdown period. The innovative system has successfully delivered on a number of levels for MINI Plant Oxford; not only improving on the ergonomic design, but also reducing the amount of time taken to complete the task.” As part of the solution, LB Foster’s in-house electronics team designed the controls for the conveyor solution and were responsible for their integration into Plant Oxford’s existing software. LB Foster Material Handling
www.conveyors.co.uk
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TGW’s materials handling solution has quadrupled volume throughput for publishing distributor, Wiley
TGW T: 01858 468855
www.tgw-
group.com Enter 361
The system has also been ergonomi- cally designed to deliver maximum efficiencies and ensure operator safety. Since going live, the system has enabled Wiley to reduce the working day from three shifts over 16 hours, to two shifts over 10 hours. Units processed per hour has increased by over 400 per cent from 3,500 to 14,400. “We chose TGW based on past expe- rience and their ability to meet our expectations on time and on budget. The system has inbuilt flexibility to cope with peaks in activity and has the potential to increase annual outbound units from the current 10 million to 30 million,” says Charly Nobbs, Wiley Vice president and director.
“The installation has also been wel- comed by staff who appreciate the ergonomic design and the improved acoustics of their new working environ- ment. The new system has resulted in significant labour savings, optimum order accuracy, a faster time to market and has provided a sustainable solution for our growing business.”
Gentle, dust-free conveyor for food A
n all-new Flexi-Disc line of tubular cable conveyors for the gentle transfer of friable food and non-food products has been introduced by Flexicon. Flexicon president David Gill says: “The new tubular cable conveyor is a strategic addition that complements Flexicon’s established line of pneumatic conveying systems, allowing us to now convey virtually any bulk solid material in the most efficient manner possible. Flexicon has engineered and thoroughly tested the new conveyor over several years to significantly advance the technology and performance associated with this conveying method.” The conveyor moves material using high-strength polymer discs – affixed to a stainless steel or galvanised cable – that slide within smooth stainless steel tubing, moving fragile products gently, quietly and dust-free, horizontally, vertically or at any angle, through small holes in walls or ceilings. The system can have single or multiple inlets and outlets, and convey over short distances or hundreds of metres. Gentle handling offered by the conveyor makes it suitable for food products that are prone
T: 0116 276 1691 Enter 362
to breakage or degradation including: cereals, coffees, teas, dried fruits, frozen vegetables, grains, nuts, peas, pet foods, seeds, snack foods and spices. Typical non-food applications include bulk chemicals, minerals, chopped fibreglass, micros- pheres, regrind, pellets, tobacco and other friable materials. Available in unlimited configurations, the conveyor is offered as a stand-alone system, or fully integrated with upstream and downstream equipment such as inlet hoppers, bag dump stations, bulk bag dischargers, bulk bag fillers, weigh batch- ing/blending systems, screeners, filling machines and storage vessels manufactured by Flexicon and others. Flexicon Europe
www.flexicon.co.uk
T: 01227 374710 Enter 363
JULY/AUGUST 2013 Materials Handling & Logistics
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