person is able to do,” comments Andy
This level of presentation precision
was one of the key drivers behind
automating the case loading operation
at Rushden. Previously, potato packs
were loaded manually into crates. It
was labour intensive, incurred packing
bottlenecks and resulted in messy tray
presentation.
STAFF SATISFACTION
Having worked on both the manual
packing and now automated lines,
machine operative Dave reflects on the
differences the robot cells have made to
workers and waste.
Noting that the UniPaker cell is much
more product and user friendly, Dave
comments: “By removing 90% of the
physical labour from the packing
A simple, intuitive
HMI means it’s easy
for operatives to
select the correct
programme and case
loading patterns for
product changeovers
“Previously, pierced bags has been one lifted, Brillopak designed the end-effector
of the downsides to using grippers using soft food-grade material.
on automated case loading systems,”
says Brillopak director David Jahn. DELTA DEXTERITY
“Additionally, when layer picking grippers For this Morrisons potato packing line,
or bomb bay doors release potatoes Brillopak installed two specialist four-
into trays, they are typically dropped in a arm Spider (Delta) robots within each
haphazard way above each tray in order robotic cell. Each robot has a payload
for the tooling to have space to open. Not of 5kg, including a head with rotation
only does this damage the product, the functionality. In most fresh produce
presentation is quite hit and miss.” applications a three-arm robot will offer
sufficient payload highlights David.
David adds: “Suctioning polybags of
production area, health & safety
and people’s approach to teamwork
has improved. It’s a much calmer
environment and so much better for
staff welfare. It’s almost hypnotic to
watch when the robots are running.”
Additionally, with the introduction of
the robotic lines and glove end effector,
Dave reports less product rework as a
result of split bags.
Describing the robot lines as easy to
operate, Dave says the system set up
and HMI is intuitive to use, particularly
for product changeovers. Having been
involved in writing guidelines for team
members to reference he affirms: “It’s
so straightforward to use that I’m never
worried about pressing the wrong
button and breaking the system!”
heavier potatoes with varied shapes is With a reach of 1130mm - 30% more equally challenging. Because it’s not a than similar sized robots - the UniPaker smooth surface, bags frequently sag and system delivers dexterity in a compact drop onto the packing conveyor, causing footprint. Rumble conveyors settle the the packing line to stop. These frequent packs and deliver them in single file into Equipment Effectiveness (OEE). Andy
line stops have a significant impact on both robotic cells, ready for automated attributes these improvements to
line efficiency and ultimately bottom line case loading. the increased packing speed, better
profit.”
Forming part of a site-wide investment
in front and back end manufacturing
improvements, the Rushden site
has seen improvements in Overall
presentation, less front to back end
“Brillopak’s robot is impressive to watch.
Rather than using stainless steel, which It never misses a beat and is capable
would add to the weight being repeatedly of orientating packs quicker than any
bottlenecks and fewer staff frustrations.
www.brillopak.co.uk
FDPP - www.fdpp.co.uk 29