BARCODING LABELLING & PACKAGING
years. Swapping out with three fully automated UniPAKer robotic crate packing systems in phase two,” reflects Matt. It was, he affirms, always central to their produce strategy of improving quality and process efficiency and reducing costs and waste.
Having got the measure of the design requirements and long-term goals at the outset, Brillopak’s Automation Architecture meant that the innovative firm had already factored in the available real estate. The team built the framework of the PAKStations to match the dimensions of the UniPAKer machines, as well as the conveyor infeed and outfeed heights; enabling a seamless and simple swap over, to mitigate any packaging disruption. “We literally pulled out the UniPAKer machines and inserted the robotic machines into the apple lines,” affirms David. Local power requirements and access points, as well as feeds to the main conveyor track for each line had already been considered at the initial due diligence planning phase. Craig Savage who project managed the entire programme, affirms that the devil really was in the detail. “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.
Another key advantage of this modular line design and phased introduction of machinery was that Brillopak was able to retain and redeploy the existing conveyors, which previously transferred crates to the PAKStations. “From a sustainability perspective, where components can be repurposed, we do, as it boosts the ROI even further,” adds David.
UPSCALLING ON 11 LINES Applying the best practice gained from phases one and two, in 2021 Thrapston completed its full- scale automation transformation with the roll out of six new linear packing lines. Handling a range
of flow-wrapped and tray-sealed fresh produce, including pears, tomatoes, apricots, blueberries and grapes, Brillopak delivered a further five UniPAKers, one PAKstation, six bale arm closers, two Crate DESTAKers and six double stackers. With 40 individual Brillopak machines now on site and running continuously, Matt upholds the value of working with a single and reliable integrator. One that can factor in all the unknowns and deliver innovative yet easy to operate ‘plug and play’ machines that talk seamlessly to each other. In particular, Matt appraises Brillopak’s foresight and deep integration knowledge. “We had a clear vision of how the linear Thrapston packing lines would ultimately look and partnered with the Brillopak engineering team throughout every phase of the process.”
This collaborative teamwork approach is a result of the personal relationship the Morrisons’ fresh produce team, site managers and engineering experts share with Brillopak. Matt expands: “The robotic packing solutions that Brillopak builds are extremely intuitive to operate and very reliable. As testament, our robot potato lines in Gadbrook continue to run as efficiently as the day they went in seven years ago. We know they are always going to work and maintain their efficiency and presentation consistency.” The smoother and gentler handling of fresh produce has been proven to reduce complaints by over 30 percent and almost instantly, reports the Head of Operations.
However, for Matt, the real Brillopak value comes from dealing with one machinery supplier. “There’s definitely something to be said for Brillopak’s amenable and accommodating approach. Integrating with other suppliers’ equipment is probably the hardest aspect. Yet, this is something I entrust to David and the engineers.
“Brillopak will often go above and beyond during the handover to ensure all their machinery is seamlessly integrated with conveyors, downstream camera graders and other equipment. Even when it’s not technically their responsibility. I don’t know of many other integrators that would undertake this level of meticulous service and support before, during or post install,” notes Matt.
The Morrisons Centre of Excellence prepares and delivers 130 million packs of fruit every year to 82 stores.
Since embarking on the first automation project with Morrisons fresh produce almost 6 years ago, Matt is adamant that this trusting collaboration with Brillopak has helped to accelerate and optimise its packing efficiency. With all five fresh produce sites now kitted out with end-to-end Brillopak machinery, a side-line benefit is how much the manufacturer has been able to streamline its stockholding of spares and components. “Dealing with one automation provider formed part of our produce directive. From a maintenance and
Brillopak’s phased approach to automation at Morrisons fresh produce operations in Thrapston
With Brillopak’s vision, Thrapston’s machinery has been designed and placed linearly and in one continuous flow from the packing hall to the chillers.
Brillopak’s Automation Architecture in situ at Morrisons Thrapston.
Award-winning end effectors and innovative yet easy to operate ‘plug and play’ machines that talk seamlessly to each other increase efficiency and packing consistency.
ongoing service perspective, dealing with one or two machinery suppliers, versus liaising with multiple contacts is evidentially more straightforward. Being able to pre-plan projects and roll automation platforms out in phases as part of a wider, aligned plan certainly helps to mitigate investment risks,” ends Matt.
Brillopack
www.brillopak.co.uk FACTORY&HANDLINGSOLUTIONS | MAY 2023 17
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