The ergonomic C130 Semi-Automated
Packstation, showcased for the first time
at PPMA 2018 and shortlisted in the PPMA
Group Awards for Most Innovative Packaging
Machinery, is a perfect example.
Designed specifically to maximise the
efficiency of manual packing operations
where full automation is not an option,
either by way of affordability or practicality,
the system is an automated version of
the traditional Lazy Susan style product
collation/packing station, and makes
each case loading line 15% more efficient.
Rather than removing humans from the
process, it helps manual workers to perform
better, making their job less arduous when
automation with consistency, due to the
packing format or high volumes of product
changeovers, is not an option.
Mansfields installed its third semi-automated
packstation recently. Lee Port, Head of
Operations comments: “What our Brillopak
C130 systems have enabled us to accomplish
is a gentler, calmer and more manageable
end-of-line packing operation, with fewer
bottlenecks.”
“Often there’s an element of paralysis by
analysis,” notes David. “Instead of agonising
over the choices, plant tours can be a
powerful way of providing factories with
direction and gauging how others have
approached automating specific tasks.
There’s no substitute for seeing things
happening in practice.”
Brillopak often puts people in touch with
different packhouse plants and accompanies
customers on visits.
As testimony, Mansfields visited Chingford
fruit packers to observe the C130 Semi-
Automated Packstation in action with
the same Redpack flow wrap line they
had recently installed. “The efficiency
improvements were immediately evident,”
reflects Lee.
CONCEPTUALISING
CONSISTENCY
Automation is imperative in food
manufacturing for consistency in quality,
production in high volumes and productivity.
The daily quest to optimise productivity
and meet tight deadlines means there’s a
drive to minimise machine downtime. A
well designed robotic case loading system
featuring easy restarts and controlled, agile
handling may provide the optimal solution
for fresh produce factories repeatedly
handling similar product and pack types.
“Accurate placement of products into crates
using robots depends upon momentum and
the control of movement by a robotic arm,”
highlights David.
For flow wrap and vertical form fill and seal
fresh produce packs, single picking can be
the safest and fastest way to control this pick
and place process and meet retailer specified
case loading patterns. Brillopak’s Unipick
P160 robotic case and crate packer also
features on this year’s PPMA stand. The
system, which averages over 100 packs p/m,
applies a combination of robotics, encoders,
vision and mechanics that provides
enhanced control and make machine restarts
less complex.
“Traditionally, to achieve anywhere
close to 100 packs p/m in robotic case
loading, machines pick layers or rows of
product,” David comments. “However, this
method tends to use mechanical devices
such as belts and turners for collating
products. This means more moving parts;
more opportunities to damage the fresh
produce items, e.g. apples, and more line
stops. These frequent line stops have a
significant impact on line efficiency and
ultimately bottom line profits.”
PICK OF THE PUNNETS
As processing lines become faster there is an
increasing need for the case loading process
to match the upstream throughput. This is
especially true in the punnet tray-sealing
arena, where products feed continuously out
of sealing machines at between 65 to 180
packs p/m.
To address this bottleneck, Brillopak is
unveiling its BR2 and BR5 Punnet Packer at
PPMA, inviting visitors to sign up for a free
one-week trial of their new concept.
Responding to market requests for a
versatile, speedy, yet affordable top seal
punnet packer, the system, which is
priced from £87,500, offers SMEs in the
fresh produce market with an affordable
mechanical style automated system.
Capable of loading up to 180 top seal
punnets and top seal trays per minute into
full and half-sized crates, as well as lipped
boxes, the BR Punnet Packer maximises
throughput by collating product into a full
layer, lifting and lowering in one seamless
motion into the crate or box.
Designed to work with all tray sealing
systems on the market today, this standard
machine also helps to reduce order, build
and installation lead times.
AUTOMATION WITHOUT
COMPROMISE
Having too much choice can be
overwhelming and making a decision about
which automated system will serve your food
business for years to come should never be a
knee jerk reaction.
The idea that robots are the answer to every
production inefficiency is a bit overcooked.
What’s clear is that there’s room for all types
of automation efficiencies, be it a Parallel
Spider-type robot, a 4-axis robot, a Cartesian
Cobot, or an improved manual packing
process that’s more ethical and sustainable
for the workforce.
To make the decision making process easier,
Brillopak has taken the step to streamline its
automation case loading menu with three
core compact, reliable and cost efficient
products - the Semi-Automated Packstation,
Unipick robots and the company’s newest
mechanical-style BR Punnet Packer.
David rationalises: “Automation reservations
in the past have centred on the prospect
of machinery obsolescence. This has been
a psychological barrier for some to fully
embrace automation, while past integration
failures may have deterred others from
looking beyond tweaking their existing
packing line. By focusing on what we are
strongest at, we hope that more factories will
recognise the opportunities that automation
has to offer.”
See the full range of Brillopak’s
automation options at PPMA
2018, Stand C50.
www.brillopak.co.uk