FOOD AND BEVERAGE n coding systems. All of the label and case information is fed into Life Health Foods’ SAP system, relaying to the palletising sorting sensors in real time, exactly what’s in each box, the manufacturing time and the pallet destination. Without interruption, 11 AmbaFlex spiral conveyors incorporating Interroll rollers move the labelled cases up and onto the overhead conveyor. Sensors on the Intralox Switch conveyor systems help to sort the cases and deliver them to the correct palletising cell. Cases that don’t have an assigned palletising line are transferred into a safe holding space. The palletising operation is streamlined and compact. To maintain the small footprint without losing any of the existing racking space, the palletising cells are located in a corner of the warehouse. Here, ve automated Endoline pallet de-stackers feed empty pallets to the three Fanuc M-410-ic robots. The robots, serving two pallet lines simultaneously, stack up to seven cases at a time onto the product pallets in the correct pattern. A paper sheet is placed between each layer. A caged shuttle moves the full pallets inside the cell for stretch wrapping. Forklifts then collect and move the wrapped pallets onto the racks. To ensure safety, the palletising operation is contained within a guarded enclosure incorporating physical safety fencing, interlocked doors, and light curtains on all openings. “The entire process from production to palletising is noticeably more ecient and streamlined,” says Edgley. “Encouraging the input from sta was especially valued. From sharing viewpoints when Endoline Robotics was scoping out the design, to now having the responsibility of overseeing the day-today maintenance of the cells, has given everyone in the team a real boost. We’ve all enjoyed learning new skills and understanding how all of the dierent automation and software elements come together. “We are now fully utilising every inch of space in a smarter, more productive way,” he adds. “The ERP reporting system especially helps us to red-ag any quality and stock issues and proactively address packing to palletising bottlenecks before they become an issue.” According to Edgley, the investment is integral to a long-term ambition of full upstream automation. “Having seen the immediate productivity bene ts from the end-of-line palletising cells, we are now eager to pull forward on our upstream automation, case sealing and packing investments,” he says. The installation, worth more than £2.5m, was the biggest in Endoline Automation's 42-year history. n Sensors on the Intralox Switch conveyor assemblies ensure that cases are delivered to the correct palletising cell.
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