Automation is set to play an increasingly larger role in safeguarding the future of the UK’s food manufacturing industry, and the Chancellor’s recent super-deduction tax allowance on plant and machinery announcement is set to give the sector the boost it needs.

While most UK food manufacturers understood the efficiencies gained from automation, adoption was at a far slower pace than other countries. However, Covid-19 has emphasised the need to update manual manufacturing practices that will prevent many from recovering quickly once social distancing measures are lifted.

According to a recent post by the International Federation of Robots (IFR) in comparison to several countries across the world, the UK was the only country, over a 10-year period, to report a 9% decrease in productivity per person.

While coronavirus has undoubtedly put a strain on global productivity, UK manufacturers faced significant issues because of workers being unable to work in production lines where they normally stand less than 50 cm apart on 12-hour shifts.

There is an established link between automation and increased productivity, so now is the time for UK manufacturers to look at long term growth and invest in automation to support labour intensive activities.

So, why have UK food manufacturers always been so reluctant to take the automation plunge?

Here, Andrew Yates, Managing Director of Endoline Automation, discusses the reasons why the UK lagged behind its global counterparts, how automated end-of-line packaging systems today meets manufacturer demands, and how machinery can be integrated into processing and packing lines quickly to ramp up output.

Demonstrating flexibility

For some food manufacturers, a wariness to change well established manual processes, and an aversion to the risks that new technologies can bring, have created major roadblocks, preventing them from reaping the many benefits automated systems can yield.

Within food manufacturing, the variability of materials has played a major factor, particularly as many believe that uniformity plays a vital role in ensuring automation runs efficiently. To meet retail demand, manufacturers are producing an abundance of brand varieties in all shapes and sizes which can cause greater complexities, due to the variation in size, shape, quality, and weight of the product.

“Retailers are constantly vying for consumer attention, creating greater choices which are continually changing. Historically, this hasn’t always lent itself well to automation and manufacturers need assurances that the investment they make in end-of-line packaging automation is future-proof.”

Fully automated end-of-line systems today can manage an unprecedented range of case styles and sizes and have been re-engineered to handle a wide variety of case materials to suit retail specifications, from poorly scored, lightweight cases, to heavy, twin wall cases. Random systems, with integrated bar code reading technology can seal random sized cases at high speed – and be reconfigured remotely to manage new sizes and orientations as and when required.

Health & Safety

Getting health and safety right has never been more paramount. Food manufactures need to adhere to stringent measures and are being set greater guidance on the use of machinery through the Food Standard Agency’s regulatory model, facing stiffer sentences if they are non-compliant.

Tougher governance around health and safety shouldn’t be a deterrent to automation, however it is vital that manufacturers do not take a CE certified machine at face value.

“There are a number of other factors which need to be considered. Manufacturers need to understand the area the machine will be located in and assess the environment for any safety concerns such as access.”

End-of-line equipment in particular presented significant hazards. Not only do they operate automatically and, in some cases, at very high speed, but the openings, to allow the cases to be transported through the system, are often large enough to be a potential for unauthorised access.

Over the years quality, end-of-line systems have been ergonomically designed offering safer operator access and the integration of Safety Light curtains not only safeguards the machine, but eliminates the need for additional safety guarding so reducing the overall footprint. Systems can also be constructed from IP65 washdown rated stainless steel.

Eliminating unnecessary downtime

Food manufacturing sites that are highly automated operate with fewer workers, resulting in a larger opportunity for uninterrupted processing. Manufacturers are currently seeking to mitigate the risk of sending people home in virus-susceptible areas within their facilities, and automation is a big part of this solution.

The risk of downtime, as a result of machinery failure, servicing or reprogramming has always been a bottleneck in the adoption of automation.

However, automation specialists have been driving the intelligence of end-of-line systems forward for some time, and there is now a greater emphasis on linking these systems together and integrating them into a customers’ own specific data network. Consequently, food manufacturers can capture, process, and analyse big data from the factory floor remotely, and improve productivity, avoid downtime through predictive maintenance, upload new case recipes, and optimise energy use.

“Our systems built today feature an integrated, Industry 4.0 compatible HMI interface enabling engineers to easily re-programme the machine to allow for new configurations of case sizes remotely via a computer, tablet or even a mobile.”

In addition, these SMART systems can be also used to monitor the machinery and send alerts on any preventive maintenance issues and spares shortages. “End-of-line systems are very self-sufficient.”

Beyond Covid-19

Automation has always been an enabler to streamline and enhance efficiency and, as a result of the pressure created by the crisis on manual process, manufacturers should now be able to clearly identify which areas would benefit from automation.

Covid-19 has undoubtedly heightened the need for the UK to integrate automation into their packing lines. By taking the steps to automate, manufacturers will be prepared for any future crisis or shutdown, while ensuring that their output levels and efficiencies remain high.

Super-deduction tax

From April until March 31^st 2023, manufacturers can qualify for a 130% capital allowance deduction. This tax break will provide 25p off company tax bills for every £1 spent on qualifying plant and machinery.

This measure – which is expected to boost UK investment by £20 billion a year – includes a super-deduction of 130% on most new plant and machinery investments, which would have ordinarily qualified for 18% relief, and a first year allowance of 50% on most new plant and machinery investments which would have ordinarily qualified for 6% relief.

Automation has always been an enabler to streamline and enhance efficiency and manufacturers should now be able to clearly identify which areas would benefit and take advantage of the 130% tax break. This will also make the UK more competitive on the global production field.

A new, fully automated Case Packer system, launched by Endoline Automation, is assisting snack processors and packers automate within compact spaces.

The Case Packer, which combines case erecting, packing, and sealing technology within one system, has been engineered to pack a range of different snack products – from pillow bags to flat bottomed bags/pouches and PET bottles.

An all in one system, the Case Packer is a cost effective alternative to installing a trio of individual machines, and has been engineered in response to rising demand from snack manufacturers who are increasingly looking to automate their packing lines, to reduce footprint, and to move away from manual labour.

With precise product handling at speeds of 12 cases per minute, the Case Packer receives single products from an infeed conveyor, groups them according to the programmed pattern on a loading platform, before lowering them into a formed case below, the filled case is then automatically closed and sealed on the top and bottom with tape.

Suitable for the packing of multi-bags of crisps, pouches of dried fruits and nuts, and PET bottles of drinks – the Case Packer system can be customised to suit specific demands, and reprogrammed for the packing of different products, formats, and quantities.

Industry 4.0 compatible technology integrated within the Case Packer can capture and make data readily available for use in “live” decision making scenarios.

The compact design also makes it the ideal solution for production areas with limited available space as the full system is in one frame, rather than having three separate machines, therefore drastically reducing footprint.

The Case Packer combines Endoline’s market leading erecting and sealing systems with case packing technology all integrated into one machine. “Endoline works with globally recognised food and beverage manufacturers, so we are aware of the increasing demand for fully automated systems which will increase efficiency, while taking up a reduced amount of floor space.

 Snacks manufacturers in particular are seeking flexible systems which can handle different packaging materials.” Andrew Yates, Sales Director of Endoline Automation explains. “We have re-engineered our case erectors and sealers to meet expectations for compact, flexible systems, but by incorporating case packing we are now able to offer a complete end of line solution.”

PPMA Total Show – Stand J120

A brand new, high speed, fully automated system, combining case erecting, packing and sealing technology will be unveiled by Endoline Machinery at the forthcoming PPMA Total Show.

As an all in one system, the Case Packer offers a compact and cost effective alternative to installing a trio of individual machines, and has been engineered in response to rising demand from UK manufacturers who are increasingly looking to automate their food packing lines, to reduce footprint, and to move away from manual labour.

With precise product handling at high speeds of 12 cases per minute, the Case Packer receives single products from an infeed conveyor, groups them according to the programmed pattern on a loading platform, before lowering them into a formed case below, the filled case is then automatically closed and sealed on the top and bottom with tape.

Suitable for handling any product packaging and orientation, the Case Packer can be customised to suit specific demands and reprogrammed for the packing of different products and quantities. Industry 4.0 compatible technology, integrated within the Case Packer can capture and make data readily available for use in “live” decision making scenarios.

The compact design also makes it the ideal solution for production areas with limited available space as the full system is in one frame, rather than having three separate machines, therefore drastically reducing footprint.

The Case Packer combines Endoline’s market leading erecting and sealing systems with case packing technology all integrated into one machine. “Working with the UK’s leading food manufacturers we are aware of the increasing demand for high speed, fully automated systems which will increase efficiency.” Andrew Yates, Sales Director of Endoline Machinery explains. “We have re-engineered our case erectors and sealers to meet expectations for high speed, flexible systems, but by incorporating case packing we are now able to offer a complete end of line solution.” 

To view the new Case Packer and other end of line system solutions from Endoline Machinery visit stand H120 at the forthcoming PPMA Total Show.

In response to manufacturer calls for flexible, future proof, end-of-line machinery, Endoline will unveil, at the forthcoming PPMA Show (Stand C52), its re-engineered 704 Fully Automatic Random Case Sealer, which can now manage an unprecedented range of case styles and sizes, meeting all current health and safety regulations.

Since its creation in the early 90’s, the 704 Fully Automatic Random Case Sealer has become a flagship system amongst Endoline’s range of end-of-line machines. In situ within food factories globally for almost 30 years, the machine is testament to Endoline’s ability to build high quality, long lasting, systems.

However, following unprecedented demand for random case sealers to manage a greater variety of case materials and sizes, Endoline has re-engineered the 704 to meet exact specifications.

Through technical enhancements Endoline have expanded the case size range by almost 60% at its greatest increase, without compromising on speed.

In addition to a greater range of case sizes, manufacturers are now packing with a wider variety of case materials to suit retail specifications, from poorly scored, lightweight cases, to heavy, twin wall cases.

To meet this challenge, Endoline have integrated a dual action hook into the re-engineered 704 to provide greater control, ensuring that the inner flaps of the case are effectively pushed into place before sealing, which overcomes tearing or the risk of the case opening at a later stage. For lighter weight cases, which are susceptible to tearing or crushing when running through a system at speed, the 704 now features side bars and a fully driven infeed with blade stop. This is automatically activated after a case passes the barcode reader to police the throughput of cases, ensuring there is a suitable gap between each, and safeguarding the consistent flow of cases into the machine.

The new infeed control also allows for greater speed control of the 704, which can now typically seal up to 14 random sized cases per minute.

“Manufacturers are increasingly pushing to automate their end-of-line production facilities, and they are facing mounting pressure from retailers to pack products into different packaging formats, and styles, to keep up with specific customer demands.” Comments Andrew Yates, Sales Director at Endoline Machinery. “Consequently, we have witnessed greater demand for systems which offer flexibility, as companies look to future proof their automation investment. To this end, random, high speed, end-of-line systems have become more sought after, and we have engineered our successful 704 to meet all of these current, high standards.”

Integrated with Endoline’s new Industry 4.0 compatible, icon based, HMI interface, the 704 is built to a smaller footprint than previous models, maximising factory floor space and features additional safety equipment to meet all current health and safety standards.

To view the 704 Fully Automatic Random Case Sealer, and other machines from Endoline’s system range, visit Stand C52 at the forthcoming PPMA Show.