For many manufacturers, time is money. Faster operation and streamlined production result in greater throughput and better manufacturing efficiency, while interruptions cause delays and increase costs.

Therefore, end-of-line bottlenecks, those points in the production process that prevent or slow production, can significantly affect overall performance. Addressing them is key to optimising efficiency, reducing costs and improving product quality.

What is a bottleneck?

A bottleneck occurs when a specific stage or operation in a manufacturing process has less capacity than the stage before or after, creating a point of congestion that slows down or limits overall throughput or output.

Some of the main end-of-line challenges that occur are:

• Downtime
  Including unexpected breakdowns and maintenance issues, downtime is a major cause of bottlenecks in manufacturing operations.
• Product damage and quality control
  Rough handling or inaccuracies during the production process can result in defects or even product recalls, causing significant delays while things are put right.
• Labour shortages
  A shortage of skilled labour, plus the fatigue and inefficiencies that come with manual handling, slows down processes such as picking and packing, causing bottlenecks.
• Packaging and labelling errors
  Poor packaging or labelling mistakes can lead to damaged goods and prevent accurate tracking, leading to delays in reporting and deliveries.

Overcoming the issue of downtime

Downtime happens when production stops or is significantly reduced, and can be planned or unplanned. Planned downtime is a scheduled shutdown for routine maintenance, upgrades or cleaning, whereas unplanned maintenance usually occurs due to an equipment breakdown or failure, or a supply chain issue. Due to its intentional nature, planned downtime can generally be accommodated in production schedules; however, standardised procedures and features such as quick-change tooling help to accelerate the process.

To minimise the risk of unplanned downtime impacting your operations, ensure you have routine inspections and preventative maintenance in place to identify mechanical issues before they escalate. AI-based diagnostics and tracking can also help with this, flagging any problems as they arise.

Reducing product damage and improving quality control

Automated handling systems such as palletisers and sack-filling machines are designed to move goods quickly and accurately, preparing them for delivery or storage.

Palletisers use a robotic arm or other mechanism to sort, transfer and stack boxes, cans, bottles and other packages onto a pallet, either in bulk or one-by-one. Specialist gripping heads ensure goods are handled with care, and additional functions such as banding and stretch wrapping protect goods during transit. Sack-filling machines fill, weigh and seal sacks and bags, ensuring they are filled to the correct capacity every time, minimising waste and improving consistency for the customer.

These systems improve accuracy and attention to detail, ensuring that each product leaving the warehouse meets the required standards. Additionally, vision inspection systems can be incorporated into machinery to catch defects early, further enhancing product quality and reducing errors.

Tackling labour issues

A combination of an ageing workforce and a lack of skills has led to a shortage of labour in the manufacturing sector, but automation can help to overcome this challenge and reduce delays.

By replacing manual tasks with equipment such as palletisers, you can free up human employees to be trained and upskilled to manage the systems, or work in more value-added roles elsewhere in the business. As well as improving efficiency, this also reduces the number of employees working in repetitive and physically demanding roles and thus lessens the risk of manual handling injuries.

There’s also the added advantage that automated systems work around the clock without the need for breaks, holidays or sick leave, enabling manufacturers to deliver consistent output and meet higher production targets.

Preventing packaging errors

Proper packaging is vital to ensure goods are protected during transit and storage. If items are damaged due to poor packaging, this can lead to delays, increased costs and customer dissatisfaction.

In addition to protecting products, packaging and labels communicate important information to customers, including supply chain data, delivery details and tracking codes. Barcodes and batch numbers are essential for tracking and identifying items, especially in the event of a recall, while for food, details such as ingredients and allergens are required by end users and to comply with regulations.

To prevent packaging problems, ensure the type of packaging being used is fit for purpose, is made from durable materials and is properly sealed.

For further advice on avoiding or overcoming end-of-line bottlenecks on your production line, contact us.

If you want to up the productivity of your manufacturing operation, you need to keep goods and materials moving efficiently around your facilities. One of the best ways to do this is by installing an automatic handling system and in this blog, we’ll look at what a handling system does and why they are so beneficial.

What is a handling system?

The term handling system refers to the machines and technology used to move, sort and pack materials and products throughout the production cycle. It may include conveyors, palletising equipment and other automated solutions that can work faster and harder than a human, speeding up processes to improve efficiency.

In a typical system, conveyors are used to move packages to a palletiser ready for stacking. The palletiser then uses a robotic arm or other mechanism to organise the products onto pallets in a predetermined configuration, ready for shipping or storage. This provides greater load stability and allows multiple loads to be moved at once.

What are the benefits of a handling system?

A well-designed handling system will integrate seamlessly with other palletising equipment already in place to streamline your operation, resulting in a cohesive manufacturing process. There are a number of other benefits too:

• Improved operational efficiency
  Handling systems allow for tasks such as loading and unloading pallets to be automated, ensuring a reliable and continuous workflow. This not only accelerates production cycles but helps to minimise downtime and boost overall output.
• Reduced labour requirement
  This brings both financial and operational savings. By using machines to carry out repetitive and labour-intensive tasks, human operatives can be redeployed to focus on more strategic or skilled activities that add more value to the business. This increases job satisfaction and reduces the likelihood of manual handling injuries occurring.
• Greater accuracy and precision
  Automated systems are designed to perform the same tasks with exacting precision, minimising the margin of error and reducing wastage. In turn, this results in a more consistent and higher quality end product, improving customer satisfaction, loyalty and repeat business.

Choosing a handling system

The choice of handling system depends on the specific needs of the manufacturing or distribution process and at PALpack we have extensive experience that allows us to recommend the best equipment for your operation.

Conveyor systems are a vital part of the production process, especially for unit load formation, and are designed according to the typology, plant layout and types of items to be palletised. Different products require different methods of handling and we always seek to understand your specific needs before any installation.

We only work with trusted providers and Lita is one of the world’s oldest manufacturers of palletising and handling systems, known for its exceptional design and build standards. Established in 1962 and still a family-owned company, its machines have been installed around the world in sectors from food to cosmetics.

The company specialises in conventional medium to high-paced palletisers, installed in tandem with other handling equipment including bottle conveyors, pallet conveyor systems, vertical elevators and pack dividers.

Many of our previous blogs have covered how automation can improve the overall effectiveness and efficiency of a manufacturing operation and handling systems are another tool to be considered. Whatever your requirement or type of operation, they can play a crucial role in improving customer service, lowering costs and staying competitive.

A national labour shortage, climate change, and soaring costs are among some of the pressures facing the food handling and storage industry right now. These businesses, like many others, are turning to automated machinery to help them weather the storm.

In this blog, we examine the trend towards automation and its potential outcomes.

Automation in food handling

Automated machinery from conveyors to ‘pick and place’ robots and AGVs (automated guided vehicles) are all being used in food handling and storage to help lighten the load.

Automated mobile robots (AMRs), for example, are used to pick products from the conveyor and pack them in pallets at the end of the production line. Automating this part of production frees up a person who can use their time elsewhere in the business. 

This stops businesses having to rely on a large workforce and reduces their overheads substantially. Not only does this solve the problem of a national shortage of skilled and unskilled workers, but it’s also having a positive impact on staff health and safety. 

How is the workforce benefiting?

Far from being a threat to the workforce, automated machinery is –  in part –  designed to take away the burden of heavy lifting.

According to industry magazine, Food Manufacturer, 1.6% of workers in warehousing suffer from musculoskeletal disorders which are a result of the strenuous lifting and carrying that comes with the job.

This is particularly pertinent to the food handling industry where products can weigh a significant amount. Using machinery to do the heavy lifting in place of people has the potential to reduce health and safety incidents.

Those team members who were once working in potentially dangerous environments, like loading bays where HGVs and forklift trucks are operating, can be moved to a safer location in the business.

What’s more, automated mobile robots can be safely programmed to work side-by-side with colleagues who have to be on the shop floor.

The trend towards automation

Automation is likely to lead to a number of positive outcomes for the food handling and storage industry. The first is a reduction in labour and operating costs – welcome news for businesses struggling with a sharp increase in their bills.  

The second though is an outcome that might surprise some people, and that’s an increase in staff retention. By automating manual and repetitive tasks, the human workforce is free to be used in other ways where they are less likely to be injured.  

“The food handling and storage industry is a great example of how using machinery can help businesses tackle the problems they are facing in an innovative way,”  said Dave Wood, Managing Director at PALpack. 

“Europe still has some catching up to do when it comes to adopting automation, but the food industry is starting to realise the positive impact that it could have on its bottom line.”

According to the International Federation of Robotics, the number of robots sold to the food and beverages industry increased by 24% in 2021 – and overall, sales in Europe went up by 15% to reach 78,000.

Material handling is an important part of the production process, but it can be a sticking point for some manufacturers. In this blog, we look at how introducing a tray-handling robot into your business could improve your line efficiency and increase throughput.

1. Quicker than manual handling

Palletising is one of the last things to be done before a product is shipped or moved into storage. A bottleneck here can have a knock-on effect further up the line, and slow down production.

Tray-handling robots are much quicker than people at doing the same job, so they can keep pace with the rest of the production line – even when it’s operating at maximum capacity.

2. Robots are much more reliable

Unlike their human counterparts, robots do not have a lunch break or holidays, and they never phone in sick. You can rely on a robot to do its job without stopping, or slowing down because it’s tired.

What’s more, a robot will consistently take the same amount of time to do a job, and always produce the same results.

3. Increase in productivity and revenue

So robots are quicker than manual handlers, and they have much less downtime. By working more efficiently, tray-handling robots can increase production and revenue. The Lita palletiser, for example, can produce up to 60 packs per minute – a significant increase on the output you might get from two or three people doing the same job manually.

4. Health and safety risks minimised

Material handling often involves a lot of repetition and heavy lifting, which carries a risk of injury. Muscle strain and joint pain are common complaints, and, in some cases, this can lead to repetitive strain injury (RSI).

By using a robot to move pallets and trays instead, you can minimise the risk of injury – and the associated staff absences that cost money in lost production hours.

5. Investing now for long-term profit

A tray-handling robot requires an upfront investment, but it will pay you back over time.

You can expect to save money on your overall wage bill, staff absences, injury payouts, and raw material wastage. With a reduction in costs and a projected rise in output, your profit margins will increase, and you’ll start to benefit from a return on your investment (ROI).

The key takeaway on tray-handling robots

If a bottleneck at the palletising stage is slowing down the rest of your production line and affecting output, then it might be time to think about investing in a tray-handling robot.

By cutting down on the number of people involved in material handling, you can reduce your labour bill, improve productivity, and increase your profit margin.

We are experienced in providing custom solutions across a range of industries, and we can help you too. For advice on taking the next steps, contact the automation experts at PALpack.

There can be many steps to moving your product through the manufacturing process. How does automation streamline this manual process, while maintaining control and protecting the goods?

Manufacturers generally have a similar flow on the shop floor:

• Materials de-palletisation and unpacking
• Manufacturing process
• Packing
• Moving or handling goods
• Palletising

Each of these actions is repetitive and manual without the aid of machinery, and each step can trigger further concerns including hygiene, health and safety and productivity.

The manufacturing itself – the making of the product – is generally the first step to involve machinery or robotics, as it ensures uniformity of product. Automation is typically a step-change introduction, with elements bolted on as production demand or capacity grows.

Packing line automation

Following the manufacturing, items need to be packed, moved and potentially stored. This can all be automated, reducing the need for human interactions with the goods.
Automating your packing line involves transport, positioning and unit load formation equipment. These conveyor systems can be integrated with existing equipment to move, control and protect goods.

Packing line automation has benefits that include:

• Items are subject to fewer breakages
• It is a more hygienic process
• There is a lowered health and safety risk
• Requirement for decision-making is reduced
• Uniformity is maintained
• Improved efficiency with fewer errors
• Increased productivity
• Packing layout is optimised

We’re going to look at some of these benefits in more detail.

Automation means fewer breakages

Breakages are part and parcel of manufacturing – people drop jars or entire boxes, or forklift accidents happen and a pallet or two goes, and we obviously write these incidents off as human error. However, employing someone who happens to be clumsy on your shop floor could quickly add up.

Employing a machine instead, you will quickly find that not only are goods shifted smoothly and efficiently, there aren’t any breakages as the robotics are programmed to simply make the same motion with the same materials. These repetitive actions can become highly complex and refined, depending on requirements.

Packing line automation is lower risk

One of the huge draws of automation in a manufacturing environment is to combat the health and safety risk to the people who are undertaking repetitive actions that put strain on their bodies. Lifting product from A to B is always manual, and there are added health and safety risks with smaller spaces or where processes overlap.

PALpack’s packing line automation

We’ve been improving manufacturer productivity with automation for over 20 years, and this experience means you get the best possible solution, with an expert advising you at every step. Get in touch for more information.