PACKAGING


automation goals and drivers. In step two, the company examines existing plant architecture to assess space, utilities, flow and potential, including technology or conveyor tracks that could be redeployed into the new space. Lastly, Brillopak examines the packaging, in terms of the product, the package types, the primary materials and the desired throughput, to define the robotic systems. The devil, re-emphasises Savage, is most definitely in the detail. “It’s a constant juggling act. Especially when maintaining packing operations while simultaneously designing and installing new lines. Frankly, from the moment the design commences to signing the order and install, the project management process becomes your entire life.” Flipping the entire packing hall layout


around 180-degrees while keeping the main track operational through all three stages of the project was logistically challenging, reaffirms Savage. It involved multiple simulations to define the best approach. New access doors and platforms were inserted and refrigeration doors were moved. Approximately one fifth of the main track was


removed along with the overhead crate feed track. To optimise efficiency a two-tiered conveyor track was proposed. Now, the lower level feeds all the clean empty crates to the 11 packing lines, while the top tier transports filled fresh produce crates to the palletiser. Given all the additional product SKUs being


processed – comprising apples, pears, tomatoes, apricots, blueberries and grapes – and totalling 130 million packs of fruit annually – the Brillopak design also needed to factor in interlinked timings at each sensor control point. Running much like a massive train set, each line calls to the Crate DESTAKers to feed crates to the robot where products are packed into the crate, gently but at high speed. To avoid packing bottlenecks and crate collisions, ‘stop’ and ‘go’ sensors at every conveyor touchpoint, including looking up through the conveyor rollers, instruct the feeding of crates to the robot UniPAKers and PAKstations in a constant cycle. With 11 adjacent lines running concurrently, the programming is seamless.


Brillopak’s patented end effectors and specialist robotics ensure a free-flowing and consistent packing process.


PUSH ON GREEN With all simulations proving the efficacy of Thrapston’s automation program, commission, build and install were given the green light. This is when the planning fun really ramps up, claims Savage. “Once GO authorisation is issued, plans become even more detailed. Brillopak updates accelerated from monthly to bi-weekly to daily and finally hourly, with all workstreams kept in the loop throughout the install. The team, in my experience, is second to none. They are knowledgeable, supportive, flexible and very easy to work with.” Using a timelapse camera, day and night Savage monitored progress against every element of his detailed plan. “When overseeing multiple contractors, and equipment is being moved in and connected overnight, it’s essential to have eyes on every aspect,” notes Savage. Staff training also needs to be factored into this plan; enabling the workforce during each switchover to have the confidence to automatically step between one packing process to another.


Citing Brillopak’s true expertise as being pick- and-place robotics, Savage is resolute that it is often the less-visible services that are so fundamental to the success of automation projects. “A machine is just that … a machine. Yet, how technology talks to each other and integrates with everything else up and down the line is where the true value rests. Projects of this scale require constant tweaks and adjustments. Having Brillopak by our side to help ensure elements aren’t missed during the scoping out phase to resolving issues, even if they are not their making, is the real value-add. From the biggest challenge to the smallest detail, they deliver on every count,” ends Savage. Over the phased installations, Thrapston installed 40 Brillopak machines spread across 11 fresh produce packing lines. The latest tally includes eight Delta robotic UniPAKers, six semi-automated ergonomic PAKStations, four crate DESTAKers, 11 bale arm closers, and 11 double stackers.


Brillopak www.brillopak.co.uk


HOW BRILLOPAK MADE A DIFFERENCE AT MORRISONS


UKManufacturing Spring 2023 27


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