MACHINE BUILDING, FRAMEWORKS & SAFETY FEATURE
RISING UP TO MEET THE GROWING
DEMAND FOR BREAD D
ue to the coronavirus pandemic, people are now buying bread to eat at home, rather
than purchasing ready-made lunches. The UK bakery market is one of the largest markets in the food industry and modern technology is needed to rise up to meet demands. But in every automated system, there are
a host of smaller components that perform simple yet essential processes. Based in Newport, South Wales, David Wood Food manufactures bread for the biggest
this year, has gained a reputation for its high-end, low maintenance products. Ten DLS4s are used in three key areas of the
production line. Two are used to push the loaves into the oven, four are used as an infeed and outfeed in the cooler, and the final four are used in the packaging area to assist with packing the loaves into the delivery baskets. DLS4 is a reliable, low maintenance, solution offering trouble-free operation from proven V guide technology and a long system life.
MOVING LOAVES Arranged in parallel and operating with a single motor, the first set of DLS4s are connected to a pusher arm which moves the trays of loaves forward onto a conveyor, into the oven operating at a temperature of over 200˚C. Working in close proximity to the oven, the double row bearings are suited to the high temperatures. HepcoMotion also offers Vacuum and Extreme Temperature bearings for either extreme high temperatures or extreme low temperature applications.
The coronavirus has led to a huge spike in demand for bread, and automation technology is essential to
keep up with demand. With actuators often an essential element of a production line in the food industry, David Wood Food, a manufacturer of bread for the biggest
retailers in the UK, is using HepcoMotion’s DLS4 belt driven actuator system
Working in parallel with a single motor
and attached to a pusher arm, one set of DLS4s push 22 loaves onto the rack, while the other set of actuators push the loaves from the rack onto the conveyor to get transported to slicing and packaging.
retailers in the UK. The company operates a fully automated production line, from the initial weighing and mixing of ingredients, to the proofing, baking and cooling, right through to the slicing and packaging. It currently produces in excess of 420k loaves a week, operating 24/7, 364 days of the year. Equipment reliability is therefore essential. There are also a further seven David Wood sites
throughout the UK manufacturing luxury meals, savoury pastries, pasties and crafted bread. A mature and fiercely competitive market, the company operates highly efficient manufacturing sites to stay a step ahead of the competition. In this high duty application, David Wood Foods
use HepcoMotion’s DLS4 belt driven actuator system which comprises belt-driven linear modules, an AC motor/inverter package and a range of compact planetary gearboxes for use with servomotors. Corrosion resistant options are also available, very often a key requirement in the food and packaging industry where regular wash/wipe downs are frequently required. HepcoMotion specialises in high quality
linear solutions and automation components and, celebrating its fifty-year anniversary
CRUMBS! Breadcrumbs and dust create a hostile environment – if particles of dirt and debris find their way beyond the seals of any linear motion component, or if they become damaged, the system will become jammed and motion will be impeded. This can result in catastrophic failure. DLS4, however, is ideally suited to this harsh environment thanks to its V guide system that functions on the basis of tight geometrical control over matching slide and bearing V’s. In turn this provides a wiping action that expels debris, keeping machines running and reliable. This self-cleaning action eliminates contamination of the slide. Hepco’s V guide systems have long re-
In operation, 32 loaves are moved at a time
and baked in the oven for over 20 minutes. The actuators are constantly repeating this process every 30 seconds, 24 hours a day, seven days a week. As a zero backlash system, the DLS4s are able to offer the greater repeatability and accuracy required for this application. The DLS4s can be specified to a bespoke length
to the nearest mm, up to 8m as standard, a benefit for David Wood Foods as variable stroke lengths suited different processes. Hepco’s DLS modules can also be supplied as joined sets to fulfil longer stroke requirements. After the loaves have baked, they are
transported to the cooler where they spend two hours rotating on a cooling rack, which helps prevent the bottom crust becoming moist and soggy. David Wood Foods has approximately 9kg of loaves in the cooler at one time.
lubrication intervals. Saving valuable downtime and cost, its cap seals need re-lubricating every 1000km, compared to every 100-150km with ball rails. In the last 12 months, re-lubrication is the only maintenance that David Wood Foods has had to carry out on the DLS4. Low maintenance cap seals are used to constantly lubricate the system and to provide effective sealing and protection. David Wood Foods requires minimal
downtime and servicing to achieve continuous operation. When a DLS4 shows sign of wear, the process is simple and does not impinge too much on production time. The eccentric adjustment facility of the V bearings can be used to quickly remove any play that has occurred. Moreover, when the V bearings reach the end of their calculated life, they can be replaced individually. The DLS4s have been in operation for nearly 10 years and the bearings have never been changed.
HepcoMotion
www.hepcomotion.com
DESIGN SOLUTIONS | APRIL 2020 15
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