Fourth generation of the Yates family joins Endoline Automation

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Endoline Automation are proud to announce that the fourth generation member of the Yates family has joined the business, with Grace Yates being appointed as Sales & Marketing Assistant for the packaging machinery manufacturer.

 

Founded in 1981 by Grace’s great-grandfather, the late Ronald Yates, Endoline is globally renowned for its engineering capabilities in the creation of packaging automation.

 

The company is currently under the steer of the third generation of the Yates family, with Andrew Yates as Managing Director and Richard Yates as Operations Director. Their father, Alan, joined his father Ronald in the 90’s before retiring but is still a regular visitor to Endoline’s Head Office in Bedfordshire today in his role as Chairman.

 

Grace has now joined the family business to work within the marketing division. Prior to joining Endoline, she studied Creative Media at Cambridge Regional College, finishing with an Extended diploma.

 

While a family firm at heart, Endoline employs 45 people, many of whom have spent their entire careers with the Company.

 

“We are delighted to welcome Grace to Endoline,” comments Andrew Yates.

 

“As a family business we have had succession plans in place for many years, and we look forward to handing on the baton for generations to come, however we firmly believe any succession plan must not be based upon the individual’s surname, but upon their integrity, professionalism, and ability. Grace has all of these attributes in abundance, and I am confident she will help Endoline reach new audiences and amplify our messages within her marketing role.”

 

A business is only as good as the people employed and the product created. We are very fortunate because we are excellent in both of these areas. We have some fantastic, dedicated, loyal and hardworking employees, who are invaluable assets to the business and an extension to our family.”  

Fully integrated packing line meets pet food manufacturer’s automation and traceability needs

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Endoline, working with Conveyor Systems Ltd, has created a customised end-of-line packing operation for GA Pet Food Partners – meeting space requirements and providing a long term automated solution which will enable the company to meet future demand.

As Europe’s leading manufacturer of own label premium dry pet foods, GA Pet Food Partners manufactures, packs and supplies pet food to some of the world’s leading pet food brands, exporting to over 50 countries worldwide.

Last year, the company invested over £80m into its Ingredients Kitchen as part of an ambitious expansion plan to develop a new dark store warehouse that will operate solely with robots and automation.

According to GA Pet Food Partners (GA), the automation of the entire process will provide its global network of partners confidence in the provenance and traceability of all recipes that are produced at the facility, while allowing for full traceability as every step is monitored.

Part of this commitment to automation included the packing process of the 80,000 tonnes of dry extruded pet food GA supplies each year.

Supplying four case erectors and its flagship 734 automatic random case sealer, Endoline worked with Conveyor Systems Ltd (CSL) to seamlessly connect each system together with conveyors to create an ergonomically friendly, automated line offering full reporting and traceability.

Modifications to meet the specification

In order to meet the wide case size range of GA, Endoline recommended the installation of two, 221 Case Erectors and two, 225 Case Erectors. While both systems are fully automatic, the 225 is designed to erect larger case sizes – up to 750mm open height. The 221 can erect up to 18 cases per minute, while the 225 runs at speeds of 10 cases per minute, providing GA Pet Food Partners with a potential case forming output of 56 cases per minute.

In addition, due to the weight variations of the filled pet food bags GA produces, between 5kg and 30kg, Endoline modified the case erectors to ensure that they were able to handle the heavy-duty cases used to hold each bag of pet food. To improve efficiency, Endoline engineers made mechanical changes to the empty case hopper on the erector to ensure the efficient and smooth delivery of cases down the hopper into the machine before erecting. The company’s unique dual opposing vacuum technology also ensures that each case is opened positively from both sides, and overcomes cases stuck together by glue migration which can happen during the case manufacturing process. The control systems on each case erector also allows for ease of case size changeover.

To maximise space efficiency, the case erectors were positioned at an angle to the line and CSL customised its conveyors to directly feed the packing line from each erector. “We designed four conveyor streams to work with each case erector. For these streams we used Interroll zero pressure, 24v accumulation roller conveyors to ensure the transportation of the cases without any risk of accumulation,” comments Jim Farquhar, Sales Director, Conveyor Systems Ltd.

A fully connected operation

Each formed case is labelled by an automatic labeller and read by a bar code reader to ensure that the size of the case corelates to the size of the pet food bag, safeguarding the smooth and efficient operation.

At the start of the line, bags full of pet food are decanted from a trolley onto an initial heavy duty plastic mattop belt conveyor, to take the loading impact, and inclined up using an incline belt conveyor. At the end of this process, a heavy duty plastic mattop conveyor was employed whereby the operator can remove the pet food bag for placement into the previously erected cartons.

Both the 24v zero pressure conveyors transporting the formed cases and the plastic mattop conveyors with bags of pet food run parallel to each other.  As many of the cartons are tall, CSL customised the carton feeding conveyor to run on a decline before being transferred, reaching the packer for ergonomic packing.

The pack station, comprised of another heavy duty mattop conveyor mounted on top of a load cell, to allow the operator to confirm the weight of the packed order, which was reported back the GA’s WMS system.

Once filled, the case is transported on a 24v zero pressure conveyor, which was again customised by CSL to incorporate a reject conveyor which diverts a case off the main line if the bar code reader determines the size/weight of it to be incorrect.

Finally, a customised incline by CSL allowed the finished packed cases to run on an incline leading up into and through to the 734 for sealing.

Endoline’s 734 Fully Automatic Random Case Sealer has the ability to seal up to 22, random sized cases per minute. Again, the system was modified by Endoline to manage the slightly longer case size runs. The high speed, award winning system uses barcode scanning technology to recognise the cases dimensions prior to sealing which is how the sealer can achieve its high throughput.

 “Through our automated systems and CSL’s experience in conveyor solutions we have created a packing line which is future-proof and able to deal with maximum output and case sizes,” comments Mark Budd, Sales Manager for Endoline Automation.

Endoline’s control systems have been interfaced with CSL’s mechanics and all of this is connected through software supplied by GA, creating a fully automated operation. “There is no room for error, and, through the software, GA can provide customers with full traceability and data reporting.” Mark comments.

Eventually, the entire packing line will be moved onto a concrete mezzanine floor within the GA warehouse. “It was vital that we created the line to fit within the required footprint. This is essentially a concept which both Endoline and CSL have proven to work well.” Mark concludes.

The entire line has been created to support GA Pet Food’s automation ambitions and the packing operation of 80,000 tonnes of dry extruded pet food

The Endoline Automation case erectors and CSL’s conveyor systems have been installed within a specific footprint so it is both ergonomically friendly, and can be later reinstated on a mezzanine floor

GA Pet Foods exports to over 50 countries worldwide


Supporting Ireland’s calls for automation

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Endoline Automation has reported an uplift in enquiries from Irish manufacturers for its end-of-line systems by almost 500% over the last 12 months.

The news follows reports that almost two-thirds of Irish businesses will be using AI or machine learning by 2023 to boost Ireland’s economic competitiveness on a global level.

“The increase we have witnessed from the Irish market has been considerable,” comments Endoline Automation’s Export Manager, James Ramsay. “Endoline has always had a good relationship with manufactures based in Ireland, including large globally recognised companies, however demand has increased fivefold.”

Celebrating its 40th anniversary last year, Endoline has achieved significant international growth due to the company’s engineering capabilities and ability to create customised solutions.

“Our award-winning, 744 Fully Automatic Random Case Sealer has set new standards in high speed, random case sealing and has proved incredibly successful in Ireland,” James continues. “This system is especially ideal for the range of big multinational companies who have based themselves in Ireland due to the logistic links. However, we are also seeing rising demand for our entry level case erecting and sealing solutions as SMEs turn to automation due to a lack of manual workers.”

Endoline has seen considerable success within the Irish egg industry over the years. Largely through the company’s links to egg grading, packing, and processing manufacturer Moba.

One such installation took place with Ballygarvey Eggs. Based in Northern Ireland, Ballygarvey supply 250 million eggs in a 60/40 split to supermarkets and foodservice customers throughout the UK and Ireland.

Back in 2016 the company faced a growth in demand and realised that their original packing plant, which was manually operated, could not sustain the volume of output required. “We designed and built a new packing plant just 5k away from the original unit.” Explains Mark Davison, Managing Director of Ballygarvey Eggs, “While this site would remain manual handling small volume lines, we wanted the new site to be a fully automation state of the art egg packing plant to deal with the number of variations in packs for our larger customers.”

With 25 different configurations of egg boxes Ballygarvey needed an automated line which was reliable, high speed and, above all, flexible to deal with the changing demands from supermarkets.  Following global demand for its 744 fully automatic random case sealer, Endoline designed and built RACE – a random automatic case erecting system to boost their SMART machinery portfolio and meet the needs of Ballygarvey.

Designed with dual opposing hoppers RACE not only allows for different sized cases to be run at any one time but downtime is eliminated as one hopper can be re-loaded with cases while the other side continues to operate.  Capable of feeding up to three packing lines at any one time RACE also incorporates Endoline’s unique dual opposing vacuum technology, which ensures each case is opened positively to overcome any tearing.

“Two different case sizes can be run on the RACE system at any one time so each hopper is loaded with cases – one size per side – and during the packing operation a sensor, fitted to the packing line conveyor, will communicate which case size is required,” James explains. “The RACE then automatically adjusts itself to form the case required and send it down the relevant line – all of this can be completed at a speed of up to 14 cases per minute. Significantly the time it takes to change or load more cases into a hopper are eliminated as, while one hopper is re-loaded, the other hopper can still be in operation.”

Once all the eggs, within the new Ballygarvey site, are checked and graded, and packed into egg boxes via Moba systems they are run through one of two packing line types. One is low speed manual operation with workers manually erecting outer boxes and filling them, via six packing lines with egg boxes. The second line features RACE which feeds formed outer boxes to a further six packing lines, which are operated by robots. However, once all the cases of eggs are filled at the 12 packing lines, they all feed into the Endoline 744 fully automatic case sealer – at a rate of 126,000 eggs per hour.

Endoline Automation’s own team of in-house engineers work with manufacturers during the installation process and offer ongoing spares and servicing support to safeguard the longevity of the systems.

James Ramsay is Endoline Automation’s Export Sales Manager

 

Endoline’s 734 fully automatic random case sealer working within Norther Ireland’s Ballygarvey factory

 

For further information on our installation at Ballygarvey Eggs please read the original case study.

Photo Credit: Management Media Belgium, Packaging Magazine

Belgium wholesaler meets efficiency and sustainable goals with Endoline and Ferag

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Endoline Automation, together with distributor Ferag, has assisted one of Belgium’s leading wholesalers, Conway, meet sustainability goals and increase efficiency with the installation of case erecting and case sealing systems.

Working across four packing lines within one of Conway’s logistics centres, the successful installation of an Endoline 225 Case Erector and two, customised Endoline 704 Case Sealers, which are handling over 3,500 boxes a day, has led to a second order within Conway’s second logistics centre. In addition, the solution has enabled the company to reduce more than half the number of full-time operators working on the lines.

While improving ergonomics for manual workers, the installation has enabled Conway to run both new and used boxes, meeting the company’s goal of reducing their carbon footprint.

“Cardboard boxes have a limited ecological footprint. But we try to go one step further by limiting as much waste as possible and recovering packaging material,” comments Conway Facility Manager, Okay Ozel. “While we no longer use boxes which do not meet our quality requirements, many are still perfectly reusable.”

Part of the Lekkerland Group, the specialist on-the-go consumption company who serves some 85,500 outlets across Europe, Conway supplies Belgian gas stations, bakeries, food retailers and quick service restaurants with convenience products, from fresh food to tobacco products.

Orders from customers are received via the Conway Group’s two logistic centres in Courcelles and Temse. To streamline the picking operation, the company introduced a robust, pick-to-light system to increase efficiency and productivity. When an order comes through, the picker is optically routed to the locations and products, which were historically then taken to four packing lines where manual workers would form the cases, pack and then seal.

To enhance efficiency further, Conway worked with Ferag in Belgium, who has successfully worked as a distributor for Endoline for over 20 years, to create a solution to automate this previously labour-intensive operation within its Courcelles site.

Due to Endoline’s unique dual opposing vacuum technology, the system can process the entire range of boxes seamlessly, including those which have previously been used, at a speed of 12 per minute. In addition, the case erector’s hopper is ergonomically positioned for ease of loading.

Two, fully automatic Endoline 704 Case Sealers were also installed at the end of the packing lines, serving two lines each. Once the formed boxes are manually filled, they are pushed down to the case sealers. Significantly, the sealers adjust themselves automatically to the size of the boxes offered, without the intervention of an operator.

Up to 32 cases per minute are sealed across both systems, meeting Conway’s desire to increase productivity. With a robust capacity to run 24/7, the systems have also enabled the company to increase capacity in the future.

“We are very happy with the installation of Endoline’s equipment.” Ozel continues. “The mixed use of recovered and new boxes can pose specific challenges to the flexibility of erectors and sealers, but we have overcome this with Endoline and Ferag’s solution.”

The Conway Group is now looking to replicate the automation within its Temse logistics center.

Image 1: Endoline Automation and distributor Ferag Belgium have installed two, fully automatic Endoline 704 Case Sealers handling over 3,500 boxes a day for Conway

Image 2: While improving ergonomics for manual workers, the installation has enabled Conway to run both new and used boxes, meeting the company’s goal of reducing their carbon footprint
Photo Credit: Management Media Belgium, Packaging Magazine


Packaging automation set to aid food manufacture growth in the wake of Covid-19

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Automation is set to play an increasingly larger role in safeguarding the future of the UK’s food manufacturing industry, according to end-of-line machinery specialist, Endoline Automation.

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 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, Sales Director for 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.

This will also make the UK more competitive on the global production field.

Covid-19 could diminish the reliance UK food factories has on manual workers in favour of fully automated systems.

 

Endoline’s Case Packer system demonstrates the high-tech, flexible capabilities of end-of-line packaging machinery.


Endoline launches Virtual Machine Demonstration service

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In the wake of a pandemic which has seen a greater reliance on technology, Endoline Machinery, while meeting demands from food manufacturers for automation, has launched a Virtual Machine Demonstration service to ensure end-of-line machinery specifications are met exactly, without the need for face-to-face interaction.

Manufacturers are increasingly looking to integrate automated and robotic systems into their processing and packing facilities to safeguard continued manufacturing, while mitigating the current restrictions placed on manual workers.

As a designer and manufacturer of both standard and customised end-of-line packaging machines, Endoline builds systems to suit a customer’s exact requirements. However, a thorough understanding of a customer’s needs is an integral element of this process, with many personnel involved.

Leveraging its experience in dealing with global customers, who often need the involvement of several manufacturing sites across the world to link up virtually to view live Factory Acceptance Tests, Endoline have packaged up this expertise within its Virtual Machine Demonstration resource.

Through live demonstrations, manufacturers can speak to a range of Endoline personnel, including sales, technical engineers, and end-of-line machinery designers to create a system which meets their specific needs. Endoline’s prime position of building machinery in-house also enables customers to ask technical questions, and view multiple functionalities of the machine during the build process.

“We are witnessing an increasing reliance on automation to streamline processing and packing lines.” Comments Andrew Yates, Sales Director at Endoline Automation. “It is essential that we continue to deliver the same level of high-quality service and diminish any challenges customers may face when installing valuable equipment during these unprecedented times.”

The fact that Endoline’s fully automated systems can also be controlled and monitored remotely further reduces the risk to personnel as it negates the need for human presence, and allows for the factory to operate remotely.

Endoline’s Virtual Machine Demonstration can be carried across virtual conferencing platforms Zoom, Skype or Microsoft Teams.

Endoline have launched Endoline’s Virtual Machine Demonstrations for customers.

 

Customers can now take full advantage of Endoline’s technical build expertise through virtual demonstrations.

Endoline’s energy efficient case sealing solution enables egg packer to increase production

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Endoline Machinery’s 704 Fully Automatic Random Case Sealer, launched just last year, has been installed within The Lakes Free Range Egg Company (The Lakes) – due to growing pressure for the Cumbria based company to pack eggs within longer than standard cases.

Endoline re-engineered its flagship, 704 case sealer in a direct response to increasing demand from food manufactures for random machinery to seal a greater variety of case materials and sizes. Through technical enhancements, Endoline expanded the case size range by almost 60% at its greatest increase.

Now, the automated, high speed solution helping enhance production for family run The Lakes, has been integrated into its state of the art egg packing facility, alongside a Moba egg grading and packing system.

Dating back to 1870, the farm has been within the Brass family for generations, but it was only under current family owners, David and Helen, that The Lakes began supplying free range eggs just over 20 years ago. Significantly, what sets The Lakes apart, is its overriding commitment to adhering to leading animal welfare, ethical and environmental principles.

As part of the company’s mission to minimise the impact on the environment, The Lakes built the state of the art, egg packing facility which it continues to grow and develop.

During the development of the system, Endoline reduced the number of cylinders on the pneumatic 704 system to dramatically lower air consumption, and improve overall energy efficiency, meeting The Lakes’ ongoing energy objectives.

Endoline raises the health & safety bar for end of line machinery

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Endoline Machinery has set the benchmark for health and safety within food manufacturing facilities across the UK with the launch of its latest system – the 704 Fully Automatic Random Case Sealer.

At the same time Endoline, who are UK leaders in the design and build of end-of-line machinery, are addressing the misconceptions food manufacturers, in particular SME’s, have around health and safety regulations and European CE Equipment Marking.

In 2016 The Food Standards Agency (FSA) began the roll out of a four year plan which will see a new, tougher regulatory model in place by 2020, which will include greater guidance on machine safety. Already, following the initial launch, food manufacturers, whose health and safety regulations do not comply, have been given stiffer sentences.

Consequently, getting health and safety right has never been more paramount, particularly as automation amongst food and drink manufacturers is still on an upward trajectory, with 73% engaged in automating their manufacturing processes at the end of last year.

With the increased governance around health and safety, safeguarding machinery in areas where manual operators also work, is a key concern amongst food manufacturers. “The over-riding objective when installing end of line systems is to increase productivity and output.” Andrew Yates, Sales Director of Endoline Machinery, explains. “As a result, many manufacturers will take a CE certified machine at face value. There are, however, a number of other factors which need to be considered, especially the risk assessment of the environment the machine will be installed within.”

While all of its machinery complies with CE regulations, Endoline stresses the importance of full transparency between customers and machinery manufacturers. “It isn’t just a case of conforming to regulations and getting the CE mark on a machine. Manufacturers need to understand the area the machine will be located in and assess the environment for any safety concerns such as access.” Andrew continues.

As testament to this, Endoline will unveil, on stand C52, its re-engineered 704 Fully Automatic Random Case Sealer – which not only meets all CE regulations, but now features an infeed Safety Light curtain as standard, and ergonomic design improvements for safer operator access.

While these additional components are not pre-requisites for CE certification, Endoline has taken them from its flagship 744 high speed, random case sealer – which is installed within blue chip food manufacturing sites across the globe.

End of line equipment can present 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.

The introduction of the infeed Safety Light curtain on the 704, not only safeguards the machine, but eliminates the need for additional safety guarding so reducing the overall footprint of the machine even further.

As a market leading manufacturer, Endoline is offering its customers comprehensive guidance and support on all matters of Health and Safety requirements surrounding their machinery. As an active member of the Working Committee for Safety of Packaging Machines EN 415-7, Endoline also stresses that health and safety features can be retrofitted to machinery to ensure that a company’s investment is future proof.

“With so much uncertainty surrounding Brexit and stringent regulations it is important that our customers see us as an authority in health and safety machinery. We continuously review safety levels of all machines and offer our customers ongoing support to ensure they remain compliant.” Andrew concludes.

Endoline’s automated solution whips up efficiency for ice cream maker

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Automating the packing process of their award winning ice-cream range with Endoline Machinery, has enabled Marshfield Farm to improve production efficiency and dramatically decrease customer lead times, while packing 30,000 litres of ice cream per day.

Family run Marshfield Farm, which is now in it’s 30th year, produces over 30 flavours of ice cream at its Wiltshire based, 1,100 acre organic farm, which is home to 250 dairy cows.

Once the ice cream is made, it is put straight into blast freezers overnight. The following day, the ice cream is packed into either 5 litre or 4 litre outer boxes, outer cases are erected, the tubs packed within them, before being sealed and shipped to over 6,000 independent retailers across the UK.

However, this process was traditionally manual and, due to retail demand for the 5 litre tubs to be packed into individual cases for easier storage, the process of packing was lengthy. Due to the frozen nature of the ice cream, it meant lead times were often longer as the packers could only manage small batch runs. “The packing time was variable when completed manually and, due to the nature of ice cream, we ran the risk of the product melting in the small window we had.” Comments Marshfield Farm owner, Will Hawking. “In addition, when manually erected and sealed, the cases were not always uniform, which left the product vulnerable further down the supply chain, and in transit to the customer.”

Realising the potential efficiency gains he could make by automating the packing process, Will contacted Endoline Machinery, who are specialists in end of line systems.

In June 2017, Endoline installed a semi-automated fully integrated line within Marshfield Farm, incorporating its 221 Fully Automatic Case Erector, conveyor systems, stainless steel packing tables, its 702 Fully Automatic Case Sealer and a Markem Imaje labeller.

Today, once the tubs of ice cream are taken from the blast freezer, the entire packing process takes just 15 seconds, a reduction in time by over 80%.

Once the cases are formed via the 221, they are transported via a powered belt conveyor to the packing stations where cages holding the product are delivered. As two manual workers are filling the cases, Endoline fitted the conveyor to an ergonomically friendly height for ease of use. The filled cases are then pushed on to a powered roller infeed conveyor to be automatically closed, and the top sealed by the 702 case sealer. Before being manually palletised, the sealed cases are run through a fully integrated print and labeller printer.

Marshfield Farm packs the ice cream in two different case sizes, one for the 5 litre tubs, and a second case size for six, 4 litre ice cream tubs.  According to Will, the process of changing the case sizes is simple and doesn’t cause any downtime.

“Automating the packing process has significantly increased our production efficiency and sped up delivery times considerably.” Will concludes. “At it’s maximum speed we are now packing 15 cases a minute, which will enable us to grow the business in the future.”

Endoline upgrades flagship sealer to help manufacturers meet efficiency goals

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In a direct bid to offer customers greater energy efficiency, Endoline Machinery have re-engineered one of its flagship random case sealers with a linear actuator system, reducing air consumption, which could ultimately reduce running costs and significantly cut a manufacturer’s carbon footprint and noise emission.

Over recent years, manufactures have significantly increased their investment in end-of-line automation. And these companies are now looking to extract every ounce of reliability and efficiency out of these turnkey lines, ensuring they deliver top performance at the lowest possible cost.

Continually evaluating every component of its systems, Endoline replaced pneumatic components on its 734 high speed random case sealer with servo driven linear actuators to reduce pneumatic supply demands. “In its old format, the 734 could consume up to 390 litres of air per minute.” Explains Keith Habben, Engineering Manager at Endoline Machinery. “When the system was first launched in 2003, it was commonly installed as a stand-alone machine. However, with manufacturers now integrating other systems to create fully turnkey lines, the requirements for overall air consumption can significantly increase and consequently, air supply and noise levels will also rise.”

Commonly driven by motors, pneumatic compressors need to run continually, consuming energy and air even when the machine is stationery. When additional machinery is added to the line, also requiring air, the pressure fluctuations can also have a detrimental effect on reliability and efficiency of the whole production line. By replacing the core pneumatic components on its 734 with the servo driven linear actuators, Endoline are set to help manufacturers reduce running costs and noise emissions significantly.

Installed within almost 100 factories globally, the high speed, fully automatic, 734 sealer can seal up to 20 random cases per minute, and is a widely respected addition to many automated lines on a snack food manufacturer’s factory floor.

Endoline upgraded a 734 machine on site at Bird Bros, a national distributor of eggs, 12 months ago in a bid to improve performance and record the improvements to line efficiency. With a weekly output of 3 million eggs, Bird Bros installed a state-of-the-art, fully automated production line several years ago with Endoline, and were welcome ‘guinea pigs’ to Endoline’s innovation.

“Since the 734 was upgraded, demand on air has reduced considerably, we have removed three air cylinders, which has made a dramatic improvement to noise emissions.”  Comments Joe Fox, Packing Centre Engineer at Bird Bros.

Endoline can upgrade all existing customers 734 machines to this new system.