Endoline Automation is set to join French distributor partner, SERPAC, at the forthcoming CFIA Rennes Exhibition – Booth 10–E4 – for the second consecutive year, following the success of their CFIA debut in 2024.

Building on the momentum from last year’s exhibition, Endoline will once again showcase its innovative packaging solutions at this unmissable food industry event. On the stand, visitors will be able to see Endoline’s 248 High Speed Glue Case Erector in action, a system that represents a significant leap forward in packaging technology.

Robustly designed to withstand the rigors of industrial environments and streamline packaging processes, the 248 Case Erector delivers exceptional results at speeds of up to 30 cases per minute. Integrated with advanced servo-drive technology for high precision, along with intuitive HMI and user-friendly software, the system also offers ease of use to minimise downtime.

The use of glue not only strengthens the integrity of the boxes for secure transit and storage but also contributes towards sustainability objectives due to the ease of recycling and the elimination of tape waste.

Offering increased productivity, reduced labour costs, and enhanced operational efficiency, the 248 Case Erector delivers a swift Return on Investment, making it the ideal exhibit at CFIA, as Endoline Automation’s Export Sales Manager, James Ramsay explains: “Following the success of our CFIA debut in 2024, we are delighted to be returning to this long-established event alongside our trusted French partner, SERPAC. The 248 Case Erector empowers businesses to optimise their packaging operations while achieving production goals, and we are excited to showcase its benefits once again to CFIA visitors.”

A British manufacturer with over 40 years of engineering expertise, Endoline Automation has a long-established reputation for engineering high-quality case erecting and case sealing machinery. With a presence in over 30 countries, through direct customer sales and distributor relationships, Endoline entered into a partnership with SERPAC in 2022.

Endoline Automation – helping food manufacturers drive efficiency and reduce energy costs

Energy consumption in the food and beverage industry has always been a considerable factor, spanning across numerous processes within the manufacturing cycle. However, with rising food costs and increasing energy prices fuelled by global events, the industry faces significant pressure to find alternative solutions to combat these escalating expenses.

It’s no longer just about productivity; managing energy cost volatility is now critical for food and beverage manufacturers navigating these economic challenges.

Recognising the urgent need for improved energy efficiency on packaging lines, Endoline Automation has introduced a groundbreaking solution that promises to make a substantial impact. By re-engineering its 248 Fully Automatic Case Erector, Endoline has integrated the innovative SMC Air Management System (AMS) to address the growing demands for energy conservation.

This new design upgrade enables manufacturers to save over 60% on energy costs, providing a welcome reprieve in an increasingly strained environment.

Compressed air has long been an essential resource within manufacturing plants, valued for being clean, safe, and readily available. However, it is also an expensive resource if not managed efficiently. Widely used to power automation in large-scale factories, compressed air accounts for up to 40% of a manufacturing facility’s total energy bill. Without effective monitoring, leak rates can be alarmingly high, resulting in wasted energy and increased operating costs.

These inefficiencies can also impact production output, further hindering profitability.

Endoline Automation’s technological innovation directly mitigates the risks associated with compressed air misuse. Working in collaboration with SMC Pneumatics UK, the company has incorporated the AMS30 Air Management System into its 248 Fully Automatic Case Erector. This advanced system continuously monitors airflow, using only the exact amount of air required. It can also automatically reduce air pressure to pre-set values and isolate the air supply when the machine isn’t operating. This level of precision dramatically reduces needless air consumption, alleviating the financial burden on manufacturers while maintaining operational efficiency.

Another critical feature of the AMS30 system is its focus on traceability. The system boasts an open dashboard with an OPC UA interface that enables manufacturers to monitor compressed air output. This data can be integrated into a customer’s monitoring system, offering a precise, real-time view of air usage. Such transparency allows manufacturers to detect and address air leaks swiftly, preventing energy waste and potential disruptions.

“Our fully automatic case erectors are already powered by servo drives for their ability to provide greater control with energy efficiency. These drives only consume power when needed, enabling instant adjustments during the case erecting process,” says Andrew Yates, Managing Director of Endoline Automation. “However, we understand that our customers are under immense pressure to cut energy costs further. With compressed air being a hidden cost driver, its efficient use is crucial. We are thrilled to offer a solution that not only reduces energy costs but also enhances the overall efficiency of our systems.”

The integration of SMC’s Air Management System (AMS) is an exciting leap forward for Endoline Automation. This system can now be incorporated into most of their packaging solutions and retrofitted into existing equipment with modifications. By offering this upgrade, Endoline Automation continues to set a new standard in sustainable, cost-effective manufacturing for the food and beverage industry.

Just like its ‘filmsake’, Endoline Automation has taken a time-traveller-themed trip, with nods to nostalgic packaging concepts of the past as well as unknown packaging hypothesis of the future.

 

Founded in 1981, Endoline Automation is to manufacturing what the DeLorean’s flux capacitator is to packaging plot twists and bending the rules of time. Now in its fifth decade and third generation of Yates leadership, Endoline’s recently showcased its legacy and enduring success as a true packaging machinery pioneer and trailblazer PPMA 2024. 

Under the title, Pack for the Future, the cast and crew explored how Endoline has helped processors adapt to each and every emerging packaging trend from the past four decades. As well as showcasing how the company continues to gain universal acceptance for its automated systems across the globe.

Throughout the eras, packaging has become synonymous with food protection, waste reduction and the ultimate symbol of convenience-culture. From the early 1980s, when barcodes were first introduced – before this every supermarket product was priced and dated manually using sticker guns – packaging has adapted to consumer needs.

In a short space of time, manufacturers focused on making products easier to carry, faster to open, quicker to reseal, simpler to dispose of, and more sustainable. Alongside this functionality, smart technologies started to roll out in the 1990s. Around the same time, extended opening hours, including Sunday shopping, was introduced.

Immortalising efficiency

With this pace of change came an unprecedented pressure among manufacturers to deliver products faster and more regularly from central distribution centres, often in more formats, packaging types and case sizes.

“The 1980s was defined by many as the Golden Era. Although it inevitably was a nostalgic time, Britain’s manufacturing powerhouse was facing its first greatest challenge – offshoring. It was a divisive decade underpinned by uncertainly, major trade reforms, industrial strikes and significant dips and fluctuations in UK manufacturing,” comment Managing Director Andrew Yates.

Without the luxury of time-travel or a crystal ball during the foundational years, Endoline Machinery’s founder Ronald Yates pre-empted that efficiency and the challenges of the time would be addressed through clever engineering and simple, yet effective automation.

From a rented room within a former corset factory, Ron designed and built his first entry level semi-automatic case sealer. The timeless classic continues to be widely sold by Endoline today. It was designed so that manufacturers could seal cases at speed and with precision. Some colleagues might still say that Ron was the original Doc Brown

 

Universal appeal

During the 90s, Endoline went from strength to strength. Its range of end-of-line packaging machines expanded to include both semi and fully automatic case erectors, case loaders, case sealers, and ergonomic hand-packing stations.

“The 1990s represented a crucial shift in manufacturing supply chains, which resulted in significant investments in logistics. A landslide Labour victory towards the end of the decade resulted in more inward investment, and in 2007 the highest manufacturing output ever was recorded by the UK,’ recalls second generation leader Alan Yates.

Having forged strong alliances with other OEM’s, Endoline began integrating its systems into manufacturing plants to create full turnkey lines. To accommodate this upscaling of the business, Endoline moved to larger premises in Biggleswade, Bedfordshire, where the team continues to operate from today.

“This was the next era representing another big shift in automation requirements. Some of this was needed to counterbalance the loss of over 1.5 million UK manufacturing jobs between 1997 and 2009,” notes Alan.

At the same time, more stringent labelling and packaging rules started to roll out, leading to the introduction of more sensors, scanners, automated labelling and talk about new Smart Factory centralised and networked systems.

 

Meta-Mania for the Age of Austerity

While Endoline maintains a strong British manufacturing presence, it has expanded its reach to over 20 countries through direct sales and distributor relationships. Likewise, the Doc Brown serial innovator mentality continues to move the company forward.

The cinematic masterpiece predicted the adoption of wearable gadgets, smart glasses, video communications, biometric identifications and even drones delivering mail and walking dogs. Once deemed far-fetched in the mid-1980s, these technologies, particularly real time data, are rapidly becoming reality.

Andrew Yates continues: “Of course, every manufacturer needs to think about the here and now and near-time gains. But what makes Endoline so different is we balance this with aligning every customer’s long term vision to their future goals.”

Andrew surmises that we all need a Marty McFly protagonist who can transport between the different eras and bend the rules a bit. “This fusion of our past successes and future outlook is part of our enduring Pack for the Future appeal. We have and we will continue to set new standards of efficiency and production transparency.”  

Testament to this success, the unique dual opposing vacuum technology engineered by the company in 1990 is rated as one of Endoline’s most pioneering technologies. But one of the company’s biggest seller is now the 744 Fully Automatic Random Case Sealer launched in 2012. This system went on to set new standards in high speed, random case sealing and was sold to snacks manufacturers across the globe.

Eager to emulate this success, Endoline has recently debuted a stronger and more sustainable Wet Paper Taper Case Erector, while Endoline Robotics has unveiled a new smaller footprint pack and palletise robotic cell. This has been designed especially for packing high-value product applications.

Now under the steer of the third generation of Yates, with Andrew Yates as Managing Director and Richard Yates as Operations Director, Endoline Automation’s distinct automation positioning combined with the power of imagination is propelling them towards a record order pipeline.

“Decades after the release of Back to the Future, the DeLorean car remains an enduring symbol of the film’s cinematic, forward-looking time-travelling adventure. A status that Endoline and our Pack for the Future automation strategy can only hope to emulate and pass on to future generations,” remarks Andrew.

 

End

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.”  

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 40^th 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.

 

 

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