Product category:
Food and drink manufacturing: processing equipment
News Release from: Marco | Subject: Factory floor efficiency system
Edited by the Manufacturingtalk Editorial
Team on 11 December 2006
Factory floor efficiency system for
rapid benefits
A rapid return on investment is just one of the benefits being enjoyed by Hall Hunter Partnership (HHP) following the installation of a Marco Trac-it MES factory floor efficiency system.
A rapid return on investment is just one of the benefits being enjoyed by leading soft fruit grower the Hall Hunter Partnership (HHP) following the installation of a Marco Trac-it MES factory floor efficiency system specifically designed for packing soft fruit Eight of Marco's bespoke ProRange LineMaster portion control workstations are at the heart of the complete weighing and material handling system installed at HHP's packhouse at Heathlands Farm near Wokingham, Berkshire
This article was originally published on Manufacturingtalk on 22 Dec 2006 at 8.00am (UK)
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A return on investment is one of the benefits being enjoyed by soft fruit grower the Hall Hunter Partnership (HHP) following the installation of a Marco Trac-It MES factory floor efficiency system.
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Twin-tier powered stainless steel conveyors, a high speed triple head label applicator and an end-of-line soft touch accumulation packing conveyor complete the comprehensive scope of supply.
The Hall Hunter Partnership is a long established family business which grows and packs a delicious array of soft fruits including strawberries, raspberries, blackberries and blueberries.
The partnership farms over 800 prime acres in the south east of England and is proud to supply leading UK supermarkets.
Further reading
Soft fruit weighing and handling
Marco has been endorsed by the success of its packing and handling solution for leading soft fruit experts Winterwood Farms.
Weighing portion control system
A second six station LineMaster portion control system supplied by Marco Weighing Systems is bringing cost savings and improved productivity to leading prepared vegetable supplier Exotic Farm Produce.
Portion control scale passes 1000 units
Production of Marco's innovative LineMaster portion control scale has passed the 1000 mark- testimony indeed to this remarkable product introduced only three years ago.
Despite significant advances in process and packaging automation technology, soft fruit packing still relies heavily on the dexterity of the manual packers and as Richard Woodcock of HHP explains: "By their nature berries vary in size, shape and of course weight, so rapid yet careful handling is essential.
To maintain competitiveness, speed is of the essence, but we have to comply with The Weights and Measures (Packaged Goods) Regulations for 'e' weighing, whilst ensuring the highest quality and minimising giveaway.
Even a few grams give away in each pack amounts to significant losses when multiplied by the millions of packs we produce each year." The Marco LineMaster workstations are designed for fast efficient packing, whilst providing the packers with an ergonomically comfortable working environment.
Although based around standard tried and tested modules, the workstations are individually designed for each application to address each client's exact requirements.
The packing stations have adjustable bench heights and the scales are flush with the packing table work surfaces.
Flexibility and mobility for the equipment is also vital, allowing customers to meet changing production needs.
The LineMaster operators take individual pre-packed punnets from the trays placed at the side of the stations and place them one at a time on the integral scales.
The LineMaster's simple, yet highly effective, 16 segment coloured bar graph immediately gives a clear indication of whether the pack is over, under or within weight tolerance.
The operators now add or remove fruits to achieve the correct target weight.
To facilitate operation, the packing stations are equipped with two separate bar graphs, one at eye level on the LineMaster control terminal, the other working in parallel, but built into the work surface adjacent to the weighing platform so that operators can focus on the quality of fruit whilst achieving an accurate punnet weight.
The operators soon 'tune in' to such visual systems and simply pack to the 'green light' without having to think about the actual weights.
This system is 'language transparent' making it ideal for multi-national operators.
When within weight tolerance, the punnets are placed on the conveyor at weigh-station level and transported down to the high speed labeller and onto the packing area.
The lower conveyor of the twin deck system has a variable speed of up to 28 metres per min and is fitted with a food grade hygienic belt.
Hinged alignment gates along the conveyor ensure the correct orientation and alignment of the punnets prior to labelling.
The top driven roller conveyor is used for transporting the empty fruit trays back towards the end of the line.
The underside of the top conveyor is covered with stainless steel cleanable panels to prevent any debris falling through onto the lower belt.
Each and every individual punnet weight is instantaneously captured by the Trac-it LineMaster system together with a record of the packer responsible.
The LineMaster system features Marco's innovative Automatic Optimisation (AO) software as part of the Trac-it MES operating suite and has been specifically developed to maximise the use of real time data capture in high speed manual packing and portion control applications.
The LineMaster stations communicate with the central PC via a secure RF wireless interface, thereby removing problems associated with external cabling and expediting line changes if required.
Pack weight trends are continually monitored by the AO system and tolerance settings at individual workstations are automatically adjusted on an ongoing basis.
These continual subtle changes, which are transparent to the operators, maintain minimal giveaway whilst ensuring packs continue to comply with average weight legislation.
The triple head labeller uses servo-driven label drives that are synchronised with the pack and conveyor speed.
This ensures accurate label positioning on the packs within +/-0.2mm.
The labeller system has touch screen controls for easy configuration and these controls are also used to operate the individual stepper motors, which move the label heads up and down to accommodate changes in pack size.
Heads one and two are contact heads whilst the third is non-contact with air blow applicator.
This also has and 360 degree rotation on the foot for applying 'flash' labels.
After labelling the packs arrive at the end of line Soft Touch Conveyor (STC) which is part of the ergonomically designed packing station, incorporating built in stainless steel tables for the operators.
The Marco system has brought important fiscal and operational benefits to the HHP operation and as Richard Woodcock concludes: "We are very pleased with the overall results and the complete system works in harmony, even at our busiest times.
The Marco engineers supervised the complete installation and commissioning, and their attention to detail has been impeccable.
Not only has our throughput gone up and our giveaway down, but we now have full traceability and can measure the effectiveness of individual operators, allowing us to optimise our levels of training.".
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