Case Study - Carton Packaging Manufacturer

Huge benefits are now being realised by a major carton packaging manufacturing plant, following installation of a new fully automated conveyor, sortation and palletising system by Welconstruct Customer Solutions.

Welconstruct Customer Solutions was chosen by the award winning packaging company to develop the solution and manage the installation of the entire packaging plant. The £600,000 investment has a payback of 2-3 years.

Whereas all cartons were once labelled, wrapped, palletised, then offloaded manually, the operation is now fully computer controlled, involving 50% less labour and is capable of handling up to 800 boxes per hour.

All output is automatically bar code labelled and transferred via an incline powered belt conveyor to a space saving mezzanine floor level. Here product is systematically sorted, through use of a bar code scanner, into one of eight lanes of an accumulating powered roller conveyor network.

Boxes are then routed, by means of a curved conveyor bend, down a straight powered roller section onto a belt and roller decline conveyor. This feeds them directly to the palletising station at ground level. An override facility exists allowing cartons to bypass the automated system, in order to be palletised manually, should the need ever arise.

For added flexibility Welconstruct Customer Solutions introduced a multi-position palletiser that enables eight pallets to be loaded almost simultaneously. When a single pallet becomes full, it is ejected onto a powered turntable, allowing another empty pallet to be automatically fed into position. The full pallet is then fed down a conveyor to the stretch-wrapping, banding and auto-labelling stations.

Safety is always a major consideration in process automation solutions. Finished pallets pass through a fire door en route to the despatch bay, where an inductive loop has been installed in the floor to ensure that the section of the conveyor here is at a standstill during any forklift unloading procedure. Control panels at both upper and lower levels provide a complete overview of the operating status of the entire system, and management have the capability to override the system at any time.

Installed during nights and weekends to minimise disruption, the new system is meeting the client's performance parameters. The Production Finishing Manager concludes: "Welconstruct Customer Solutions was very proactive throughout the design and implementation stages in helping to resolve our handling problems. As a result we are already realising the efficiency and productivity gains required to maintain our competitiveness within the marketplace."


home about us meeting YOUR needs workspace solutions supply chain solutions cleanroom solutions sterile services automotive - OEM automotive - retail case studies workspace supply chain sterile services evaporative cooling contact us location map latest news site map 01384 267070	Case Study - Carton Packaging Manufacturer Huge benefits are now being realised by a major carton packaging manufacturing plant, following installation of a new fully automated conveyor, sortation and palletising system by Welconstruct Customer Solutions. Welconstruct Customer Solutions was chosen by the award winning packaging company to develop the solution and manage the installation of the entire packaging plant. The £600,000 investment has a payback of 2-3 years. Whereas all cartons were once labelled, wrapped, palletised, then offloaded manually, the operation is now fully computer controlled, involving 50% less labour and is capable of handling up to 800 boxes per hour. All output is automatically bar code labelled and transferred via an incline powered belt conveyor to a space saving mezzanine floor level. Here product is systematically sorted, through use of a bar code scanner, into one of eight lanes of an accumulating powered roller conveyor network. Boxes are then routed, by means of a curved conveyor bend, down a straight powered roller section onto a belt and roller decline conveyor. This feeds them directly to the palletising station at ground level. An override facility exists allowing cartons to bypass the automated system, in order to be palletised manually, should the need ever arise. For added flexibility Welconstruct Customer Solutions introduced a multi-position palletiser that enables eight pallets to be loaded almost simultaneously. When a single pallet becomes full, it is ejected onto a powered turntable, allowing another empty pallet to be automatically fed into position. The full pallet is then fed down a conveyor to the stretch-wrapping, banding and auto-labelling stations. Safety is always a major consideration in process automation solutions. Finished pallets pass through a fire door en route to the despatch bay, where an inductive loop has been installed in the floor to ensure that the section of the conveyor here is at a standstill during any forklift unloading procedure. Control panels at both upper and lower levels provide a complete overview of the operating status of the entire system, and management have the capability to override the system at any time. Installed during nights and weekends to minimise disruption, the new system is meeting the client's performance parameters. The Production Finishing Manager concludes: "Welconstruct Customer Solutions was very proactive throughout the design and implementation stages in helping to resolve our handling problems. As a result we are already realising the efficiency and productivity gains required to maintain our competitiveness within the marketplace."
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